Wagner SprayTech Paint Sprayer B_04001 User Manual
Translation of the Original  
Operating Manual  
Version 12/2012  
Pneumatic Double  
Diaphragm Pump  
ZIP52 - ZIP80  
B_04001  
B_04002  
B_04003  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Contents  
1
ABOUT THESE INSTRUCTIONS  
Preface  
Warnings, Notes and Symbols in these Instructions  
Languages  
5
5
5
6
6
1.1  
1.2  
1.3  
1.4  
Abbeviations in the Text  
2
CORRECT USE  
Device Types  
Type of Use  
Use in Potentially Explosive Areas  
Safety Parameters  
Processing Materials  
Reasonably Foreseeable Misuse  
Residual Risks  
7
7
7
7
8
8
9
9
2.1  
2.2  
2.3  
2.4  
2.6  
2.6  
2.7  
3
3.1  
3.2  
IDENTIFICATION  
Explosion Protection Identification  
Maximum Surface Temperature  
10  
10  
10  
4
4.1  
GENERAL SAFETY INSTRUCTIONS  
Safety Instructions for the Operator  
11  
11  
11  
11  
11  
11  
12  
12  
12  
13  
13  
13  
14  
14  
14  
14  
14  
14  
15  
15  
16  
16  
16  
16  
16  
4.1.1 Electrical Equipment  
4.1.2 Personnel Qualifications  
4.1.3 Safe Work Environment  
4.2  
Safety Instructions for Staff  
4.2.1 Safe Handling of WAGNER Spray Units  
4.2.2 Grounding the Unit (Except for Non-Conductive Plastic Units)  
4.2.3 Material Hoses  
4.2.4 Cleaning  
4.2.5 Handling Hazardous Liquids, Varnishes and Paints  
4.2.6 Touching Hot Surfaces  
4.2.7 Explosion Hazard  
4.2.8 Noise Risk  
4.2.9 Material Chemical Compatibility  
4.2.10 Emergency Stop  
4.2.11 Tightness Check  
4.2.12 Maintenance  
4.3  
Use in Areas Subject to Explosion Hazards  
4.3.1 Safety Regulations  
4.3.2 Operation without Fluid  
4.3.3 Maximum Surface Temperature  
4.3.4 Maximum Surface Temperature - Exothermic Reactions  
4.3.5 Connection Pipes  
4.3.6 Pump Protection  
5
5.1  
5.2  
DESCRIPTION  
Areas of Application  
Scope of Delivery  
17  
17  
17  
3
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VERSION 12/2012  
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OPERATING MANUAL  
Contents  
5.3  
Data  
17  
17  
18  
18  
20  
22  
24  
26  
5.3.1 Materials of the Fluid Transporting Parts  
5.3.2 Technical Data  
5.3.2.1 Technical Data for Metallic Pumps  
5.3.2.2 Technical Data for Non-Metallic Pumps  
5.3.3 Dimensions and Connections  
5.3.4 Performance Diagrams  
5.4  
Mode of Operation  
6
ASSEMBLY AND COMMISSIONING  
Transportation  
Storage  
Assembly  
Grounding (Except for Non-Conductive Plastic Units)  
Commissioning  
27  
27  
27  
27  
30  
32  
32  
33  
34  
6.1  
6.2  
6.3  
6.4  
6.5  
6.5.1 Safety Regulations  
6.5.2 Preliminary Operations  
6.5.3 Unit Pressure Tightness Test  
7
OPERATION  
Operation  
Ending Work  
Storage over Longer Periods of Time  
35  
35  
35  
35  
7.1  
7.2  
7.3  
8
TROUBLE SHOOTING AND PROBLEM SOLVING  
36  
9
MAINTENANCE  
Safety Instructions  
38  
39  
39  
41  
41  
42  
42  
42  
9.1  
9.2  
9.3  
9.4  
9.5  
9.6  
9.7  
Diaphragm Replacement (Preventive Maintenance)  
Diaphragm Replacement (Due to Breakage)  
Cleaning / Replacement of the Suction and Delivery Ball Valves  
Replacement of the Reversing Valve  
Material Hoses  
Decommisioning  
10  
ACCESSORIES  
43  
11  
SPARE PARTS  
45  
45  
46  
48  
50  
52  
54  
56  
58  
11.1  
11.2  
11.3  
11.4  
How can Spare Parts be Ordered?  
ZIP52 Pump - Metal - Universal Connections  
ZIP52 Pump - Metal - Independent Connections  
ZIP52 Pump - Conductive Acetal  
11.45 ZIP52 Pump - Polypropylene - Universal Connections  
11.6  
11.7  
11.8  
ZIP80 Pump - Aluminum - Universal Connections  
ZIP Motor  
Service Sets  
12  
GUARANTEE AND CONFORMITY DECLARATIONS  
Important Notes Regarding Product Liability  
Guarantee Claim  
59  
59  
59  
60  
12.1  
12.2  
12.3  
CE Declaration of Conformity  
4
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
1 ABOUT THESE INSTRUCTIONS  
1.1 PREFACE  
The operating manual contains information about safely operating, maintaining, cleaning  
and repairing the device.  
The operating manual is part of the device and must be available to operating and service  
staff.  
The operating and service staff should be instructed according to the safety instructions.  
The device may only be operated in compliance with this operating manual.  
This equipment can be dangerous if it is not operated according to the definitions in this  
operating manual.  
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS  
Warning instructions in this operating manual highlight particular dangers to users and  
device and state measures for avoiding the hazard. These warning instructions fall into the  
following categories:  
DANGER  
Danger - immediate risk of danger.  
Non-observance will result in death or serious injury.  
This information warns you of a hazard!  
Possible consequences of not observing the warning instructions.  
The signal word indicates the hazard level.  
The measures for preventing the hazard and its  
consequences.  
WARNING  
Warning - possible imminent danger.  
Non-observance may result in death or serious injury.  
This information warns you of a hazard!  
Possible consequences of not observing the warning instructions.  
The signal word indicates the hazard level.  
The measures for preventing the hazard and its  
consequences.  
CAUTION  
Caution - a possibly hazardous situation.  
Non-observance may result in minor injury.  
This information warns you of a hazard!  
Possible consequences of not observing the warning instructions.  
The signal word indicates the hazard level.  
The measures for preventing the hazard and its  
consequences.  
NOTICE  
Notice - a possibly hazardous situation.  
Non-observance can cause material damage.  
This information warns you of a hazard!  
Possible consequences of not observing the warning instructions. The signal word  
indicates the hazard level.  
The measures for preventing the hazard and its consequences.  
Note - provides information about particular characteristics and how to proceed.  
5
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
1.3 LANGUAGES  
The operating manual is available in the following languages:  
Language:  
German  
Italian  
Order No.  
2330425  
2332230  
Language:  
English  
French  
Order No.  
2330426  
2335553  
Spanish  
2335555  
1.4 ABBEVIATIONS IN THE TEXT  
Number of pieces  
Position  
Marking in the spare parts lists  
Order number  
Order No.  
Double stroke  
Materials:  
POM  
Polyoxymethylen (Acetal)  
Polypropylene Polypropylene  
PPS  
Polypropylene sulfide  
PTFE  
Polytetrafluorethylene  
UHMWPE  
High molecular weight Polyethylene  
6
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
2 CORRECT USE  
2.1 DEVICE TYPES  
A) Metallic versions (aluminum and stainless steel):  
Pneumatic double diaphragm pumps with order number  
U550.ATRD7  
U550.ATSS7  
U550.ATSS8  
U550.STSS7  
U551.ATSS7  
U551.303  
U555.ATSS7  
B) Conductive Acetal versions:  
Pneumatic double diaphragm pumps with order number  
U552.GHSS1  
U552.GHSS7  
U553.GTSS1  
C) Non-conductive polypropylene versions:  
Pneumatic double diaphragm pumps with order number  
U552.PTSS7  
U553.PHSD7  
U553.PTSS7  
2.2 TYPE OF USE  
A) Metallic versions (aluminum and stainless steel) and conductive Acetal:  
The unit is suitable for working liquid materials like paints and varnishes in accordance  
with the classification into explosion classes IIA or IIB.  
B) Non-conductive polypropylene versions:  
The unit is suitable for working liquid materials like paints and varnishes.  
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS  
A) Metallic versions (aluminum and stainless steel) and conductive Acetal:  
The pneumatic double diaphragm pumps can be employed in explosion hazard zones  
(Zone 1).  
B) Non-conductive polypropylene versions:  
The pneumatic double diaphragm pump must be employed outside of explosion hazard  
zones.  
7
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
2.4 SAFETY PARAMETERS  
WAGNER accepts no liability for any damage arising from incorrect use.  
Use the unit only to work with the materials recommended by WAGNER.  
Operate only the entire unit.  
Do not deactivate safety fixtures.  
Use only WAGNER original spare parts and accessories.  
The operation of the pneumatic double diaphragm pump may is only allowable under  
the following conditions:  
The operating staff have previously been trained on the basis of this operating  
manual.  
The safety regulations listed in this operating manual are observed.  
The operating, maintenance and repair information in this operating manual is  
observed.  
The statutory requirements and accident prevention regulations standard in the  
country of use are observed.  
2.6 PROCESSING MATERIALS  
Fluid materials like paints and varnishes.  
NOTICE  
Abrasive materials and pigments!  
Greater wear of the parts carrying the material.  
Use the application-oriented model (flow rate/cycle, material, valve, etc.) as  
indicated in section 5.3.2.  
Check if the fluids and solvents used are compatible with the pump construction  
materials as indicated in section 5.3.1.  
8
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
2.6 REASONABLY FORESEEABLE MISUSE  
The following is prohibited:  
coating work pieces which are not grounded,  
unauthorized conversions and modifications to the device,  
processing dry or similar coating materials,  
using defective components, spare parts or accessories other than those described  
in chapter 10 of this operating manual.  
The forms of misuse listed below may result in health issues and/or damage to property:  
use of powder as coating material  
and incorrectly set values for the processing.  
Wagner double diaphragm pumps are not designed for pumping food.  
2.7 RESIDUAL RISKS  
Residual risks are risks which cannot be excluded even in the event of correct use.  
If necessary, warning and prohibition signs at the relevant points of risk indicate residual  
risks.  
Residual risk  
Source  
Consequences  
Specific measures Lifecycle phase  
Skin contact with  
paints and cleaning and cleaning agents  
agents  
Handling of paints Skin irritation,  
Wear protective  
clothing  
Observe safety data maintenance,  
Operation,  
allergies  
sheets  
disassembly  
Paint in air outside Painting outside the Inhalation of  
the defined working defined working substances which  
area area  
Observe working  
and operating  
instructions.  
Operation,  
are hazardous to  
health  
maintenance  
9
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
3 IDENTIFICATION  
3.1 EXPLOSION PROTECTION IDENTIFICATION  
A) Metallic versions (aluminum and stainless steel) and conductive Acetal:  
Pneumatic double diaphragm pumps with order number  
U550.ATRD7  
U550.ATSS7  
U550.ATSS8  
U550.STSS7  
U552.GHSS1  
U552.GHSS7  
U551.ATSS7  
U551.303  
U553.GTSS1  
U555.ATSS7  
As defined in the Directive 94/9/EC (ATEX 95), the unit is suitable for use in areas where  
there is an explosion hazard.  
+4°C Tamb +40°C  
European Communities  
Symbol for explosion protection  
Unit class II  
Category 2 (Zone 1)  
Ex-atmosphere gas  
Explosion group  
Temperature class: maximum surface temperature < 135 °C; 275 °F  
Tamb  
+4 °C to +40 °C: permissible ambient temperature area  
3.2  
MAXIMUM SURFACE TEMPERATURE  
Maximum surface temperature:  
Permissible ambient temperature:  
the same as the permissible material temperature.  
see under Technical data, Section 5.3.2.  
10  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
4 GENERAL SAFETY INSTRUCTIONS  
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR  
Keep this operating manual at hand near the device at all times.  
Always follow local regulations concerning occupational safety and accident  
prevention.  
4.1.1 ELECTRICAL EQUIPMENT  
Electrical devices and equipment  
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  
regulations.  
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.  
4.1.2 PERSONNEL QUALIFICATIONS  
Ensure that the device is operated and repaired only by trained persons.  
4.1.3 SAFE WORK ENVIRONMENT  
Make sure that the floor in the area where you are working is electrostatically  
conductive in accordance with EN 61340-4-1.  
Ensure that all persons within the working area wear electrostatically conductive  
shoes.  
Ensure that during spraying, persons wear electrically conductive gloves. The  
grounding via the handle of the spray gun.  
Paint mist extraction systems must be fitted on site according 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 flames, sparks, glowing wires  
or hot surfaces in the vicinity. Do not smoke.  
4.2 SAFETY INSTRUCTIONS FOR STAFF  
Always follow the information in these instructions, particularly the general safety  
instructions and the warning instructions.  
Always follow local regulations concerning occupational safety and accident  
prevention.  
11  
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VERSION 12/2012  
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OPERATING MANUAL  
4.2.1 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 device, 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.  
- In case of functional faults: Identify and correct the problem, proceed as described in  
Chapter "Trouble Shooting".  
The liquid emitters are to be checked for safe working conditions by an expert (e.g.  
Wagner Service Technician) as often as necessary or at least every 12 months, in  
accordance with the guidelines for liquid emitters (ZH 1/406 and BGR 500 Part 2  
Chapter 2.36).  
- For shut down devices, the examination can be suspended until the next start-up.  
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 a position.  
4.2.2 GROUNDING THE UNIT (EXCEPT FOR NON-CONDUCTIVE PLASTIC UNITS)  
Depending on the electrostatic charge and the flow speed of the spray, an electrostatic  
charge may occur in the equipment. In the event of discharge, this may result in the  
formation of sparks or flames.  
Ensure that the unit is grounded for every spraying operation.  
Ground the work pieces to be coated.  
Ensure that all persons inside the working area are grounded, e.g. that they are wearing  
electrostatically conductive shoes.  
Wear electrostatically conductive gloves when spraying. The grounding via the spray  
gun handle.  
4.2.3 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.  
Make sure that the hoses are laid only in suitable places. In no case, should hoses be  
laid in the following places:  
– in high traffic areas,  
– on sharp edges,  
– on moving parts or  
– on hot surfaces.  
Make sure that the hoses are never used to pull or move the equipment.  
The electrical resistance of the complete high pressure hose must be less than 1 MOhm.  
12  
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VERSION 12/2012  
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OPERATING MANUAL  
Several liquids have a high expansion coefficient. In some cases its volume can rise with  
consequent damage to hoses, fittings and cause fluid leakage.  
When the pump sucks liquid from a closed container, ensure that air or suitable gas can  
enter the container to avoid a vacuum being generated in the container itself. So that a  
negative pressure is avoided. The vacuum could implode the container (squeeze) and can  
break. The container would leak and the liquid flow out.  
The pressure ratio is 1:1. Therefore the pressure generated by the pump is equal to the  
input air pressure.  
4.2.4 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  
temperature.  
To clean, use cloths and brushes moistened with solvent. 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.  
Ground the container.  
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS  
When preparing or working with paint and when cleaning the unit, follow the working  
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 a 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.  
4.2.6 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 > 43 °C; 109.4 °F:  
- Identify the unit with a warning sticker "Warning - hot surface".  
Order No.  
9998910  
9998911  
Instruction sticker  
Protection sticker  
Note: The two stickers order together.  
13  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
4.2.7 EXPLOSION HAZARD  
Do not ever use chloride or halogenated solvents (such as trichlorothane and methylene  
chloride) with units containing aluminum or galvanized and zinc-plated parts. As they may  
react chemically thus producing an explosion danger.  
Read the classification and information leaflet concerning the product and solvent to be  
used.  
4.2.8 NOISE RISK  
In some working conditions, the pump can be particularly noisy: for example when the  
air feeding pressure is high and when there is no pressure or a very low pressure in the  
pumped fluid (free flow operation). In these cases, all personnel working next to the pump  
shall wear adequate individual protections and/or use valves and seats in plastic material,  
provided the working conditions and the compatibility with the pumped fluid allow it.  
4.2.9 MATERIAL CHEMICAL COMPATIBILITY  
Make sure the materials employed in manufacturing the pump are chemically compatible  
with the fluid to be pumped. A wrong choice can cause harming people (as a result of  
prosection of noxious and irritant products) as well as polluting the environment, besides  
prematurely damaging the pump and its hoses.  
4.2.10 EMERGENCY STOP  
To quickly stop the unit in case of emergency, close the air cutoff valve or the pressure  
regulator; to interrupt the air supply to the pump’s motor. Cutoff valve is not supplied with  
the pump. It has to be provided and properly installed by the user.  
Caution: delivery circuits of pneumatic pumps can remain pressurized, even when the air  
input valve is closed.  
4.2.11 TIGHTNESS CHECK  
When using the pump after a long period of inactivity, check tightness of all parts subject  
to pressure.  
4.2.12 MAINTENANCE  
Depending on the type of use and the substances used, the user has to periodically check  
for presence of deposits as well as its cleanliness, the state of wear of the components and  
proper operation of the pump assembly.  
The operation has to be carried out in conformity with what is written in this manual.  
14  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
4.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS  
Only the pneumatic double diaphragm pump in metal (aluminum and stainless steel) and  
conductive Acetal can be used in explosion hazard zones. The following safety regulations  
must be observed and followed.  
4.3.1 SAFETY REGULATIONS  
Safe handling of WAGNER spray units  
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 material  
Check that the ignition temperature of the pumped material is higher than the max.  
allowable surface temperature.  
Medium supporting atomizing  
To atomize the material, use only weakly oxidizing gases, e.g. air.  
Surface spraying, electrostatic  
Do not spray system parts with electrostatic.  
Cleaning  
If there are deposits on the surfaces, the unit may form electrostatic charges. Flames or  
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.  
15  
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VERSION 12/2012  
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OPERATING MANUAL  
4.3.2 OPERATION WITHOUT FLUID  
Avoid running the pump sucking air, without fluid inside. The air, combined with the  
vapour of flammable fluids, can generate internal areas with an explosion hazard.  
Periodically check that the pump is working regularly, paying special attention to presence  
of air in the pumped fluid, which may be caused by a breakage in the pump.  
Avoid operating the pump with damaged diaphragms.  
4.3.3 MAXIMUM SURFACE TEMPERATURE  
The maximum surface temperature of the pump depends on the temperature of the  
pumped fluid, that must not exceed the values indicated in the section "Technical Data".  
4.3.4 MAXIMUM SURFACE TEMPERATURE - EXOTHERMIC REACTIONS  
Fluids incompatible with the pump’s materials or particularly reactive mixtures of products  
with several components may cause exothermic reactions and develop dangerous  
temperatures or pressure.  
4.3.5 CONNECTION PIPES  
Connection cables must be made of conductive material and properly grounded.  
4.3.6 PUMP PROTECTION  
If the pumping fluids contain solid particles, install a filter on the intake circuit. This  
prevents particles, that are large enough to damage the internal parts of the pump, from  
entering. Refer to the paragraph Technical Data to verify the maximum size of solids that  
can be pumped.  
Keep the metal surfaces clean. Electric conductivity of the surfaces is essential for explosion  
protection.  
Frequently clean the equipment so as to prevent residue of insulating substances from  
accumulating.  
Do not use rusted parts or metal tools that may cause sparks of a mechanical origin inside  
the explosion hazard area.  
16  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
5 DESCRIPTION  
5.1 AREAS OF APPLICATION  
NOTICE  
Abrasive materials and pigments!  
Greater wear of the parts carrying the material.  
Use the application-oriented model (flow rate/cycle, material, valve, etc.) as  
indicated in section 5.3.2.  
Check if the fluids and solvents used are compatible with the pump construction  
materials as indicated in section 5.3.1.  
5.2 SCOPE OF DELIVERY  
-
Diaphragm pump  
CE-Conformity  
Operating manual German  
Operating manual for other languages  
See Chapter 12  
Order No.: 2330425  
See Chapter 1  
The delivery note shows the exact scope of delivery.  
Accessories: see Chapter 10  
5.3 DATA  
5.3.1 MATERIALS OF THE FLUID TRANSPORTING PARTS  
Pump No. Pump body Diaphragm Diaphragm disc Valve seat  
Valve ball  
O-rings  
U550.ATRD7 Aluminum  
PTFE  
PPS  
PPS  
Acetal (POM) PTFE  
U550.ATSS7  
U550.ATSS8  
U550.STSS7  
U551.ATSS7  
U551.303  
U552.GHSS1 Acetal (POM)  
U552.GHSS7 Acetal (POM)  
U552.PTSS7  
U553.GTSS1  
Aluminum  
Aluminum  
Stainless steel  
Aluminum  
Aluminum  
PTFE  
PTFE  
PTFE  
PTFE  
PPS  
PPS  
PPS  
PPS  
PPS  
POM  
POM  
Polypropylene  
POM  
Stainless steel Stainless steel PTFE  
Stainless steel Stainless steel PTFE  
Stainless steel Stainless steel PTFE  
Stainless steel Stainless steel PTFE  
Stainless steel Stainless steel PTFE  
Stainless steel Stainless steel PTFE  
Stainless steel Stainless steel PTFE  
Stainless steel Stainless steel PTFE  
Stainless steel Stainless steel PTFE  
Stainless steel Acetal (POM) PTFE  
Stainless steel Stainless steel PTFE  
Stainless steel Stainless steel PTFE  
PTFE  
UHMWPE  
UHMWPE  
PTFE  
PTFE  
UHMWPE  
PTFE  
Polypropylene  
Acetal (POM)  
U553.PHSD7 Polypropylene  
U553.PTSS7  
U555.ATSS7  
Polypropylene  
Polypropylene  
PPS  
Polypropylene  
Aluminum  
PTFE  
Positions of the individual parts: see spare parts list.  
17  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
5.3.2 TECHNICAL DATA  
5.3.2.1 TECHNICAL DATA FOR METALLIC PUMPS  
Description  
Unit  
Wetted parts materials  
Transmission ratio  
Flow volume per double  
stroke (DH)  
1:1  
108  
1:1  
108  
1:1  
62  
1:1  
225  
cm³  
cc  
Maximum operating  
pressure  
MPa  
bar  
0.8  
8
0.8  
8
0.8  
8
0.8  
8
psi  
116  
490  
52  
13.7  
0.15  
1.5  
22  
116  
490  
52  
13.7  
0.15  
1.5  
22  
116  
490  
28  
7.4  
0.10  
1.0  
15  
116  
360  
80  
21.1  
0.22  
2.2  
32  
Maximum possible speed  
Maximum flow rate  
(free flow - flooded inlet)  
Minimum air inlet pressure  
DH/min  
l/min  
GPM  
MPa  
bar  
(1)  
psi  
Maximum air inlet pressure  
MPa  
bar  
0.8  
8
0.8  
8
0.8  
8
0.8  
8
psi  
116  
116  
116  
116  
Air inlet connection (male)  
Maximum suction height  
BSP(R)  
m
ft  
m
1/4"  
4.8  
15.7  
2.7  
9
4.8  
15.7  
2.7  
9
2.8  
9.2  
2.2  
4.9  
16  
2.7  
9
(2)  
(3)  
ft  
7.2  
Maximum solid body size  
mm  
inches  
2.0  
0.08  
2.0  
0.08  
2.0  
0.08  
3.0  
0.12  
Sound pressure equivalent  
50 cycles/min  
(feeding 5 bar)  
(4)  
dB(A)  
dB(A)  
73  
85  
73  
85  
73  
85  
79  
91  
Sound pressure equivalent  
maximum flow rate  
(feeding 8 bar)  
Sound power at maximum  
flow rate (feeding 8 bar)  
Fluid connections  
(inlet & outlet bush)  
Weight  
(4)  
(5)  
dB(A)  
99  
99  
99  
102  
BSP(G)  
1/2"  
1/2"  
1/2"  
3/4"  
kg  
lb  
3.7  
8.1  
6.0  
13.2  
3.7  
8.1  
5.3  
11.7  
Maximum material  
pressure at the pump's  
inlet  
MPa  
bar  
psi  
0.1  
1
14.5  
18  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Description  
Unit  
Wetted parts materials  
Material temperature  
Ambient temperature  
°C  
°F  
°C  
°F  
+4÷90  
+4÷90  
+4÷90  
+4÷90  
+39÷194 +39÷194 +39÷194 +39÷194  
+4 ÷ +40  
+39 ÷ +104  
Allowable sloping position  
for operation  
10°  
(1) PF = Perfect Flow = low pulsation pump with a shorter stroke  
(2) Pump with stainless steel valves (start condition: empty pump / dry valves)  
(3) Pump with plastic valves (start condition: empty pump / dry valves)  
(4) LqA (10s)  
(5) (ISO 3744  
WARNING  
Outgoing air containing oil!  
Risk of poisoning if inhaled.  
Air motor switching problems.  
Provide compressed air free from oil and water (quality standard  
5.5.4 according to ISO 8573.1)  
5.5.4 = 40 μm / +7 / 5 mg/m³.  
19  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
5.3.2.2 TECHNICAL DATA FOR NON-METALLIC PUMPS  
Description  
Unit  
Wetted parts materials  
Transmission ratio  
Flow volume per double  
1:1  
108  
1:1  
62  
1:1  
108  
1:1  
62  
cm³  
cc  
stroke (  
)
Maximum operating  
pressure  
MPa  
bar  
psi  
0.8  
8
116  
490  
52  
13.7  
0.15  
1.5  
22  
0.8  
8
116  
490  
28  
7.4  
0.10  
1.0  
15  
0.8  
8
116  
490  
52  
13.7  
0.15  
1.5  
22  
0.8  
8
116  
490  
28  
7.4  
0.10  
1.0  
15  
Maximum possible speed  
Maximum flow rate  
(free flow - flooded inlet)  
Minimum air inlet pressure  
/min  
l/min  
GPM  
MPa  
bar  
(1)  
psi  
Maximum air inlet pressure  
MPa  
bar  
0.8  
8
0.8  
8
0.8  
8
0.8  
8
psi  
116  
116  
116  
116  
Air inlet connection (male)  
Maximum suction height  
BSP(R)  
m
ft  
m
1/4"  
4.8  
15.7  
2.7  
9
2.8  
9.2  
2.2  
4.8  
15.7  
2.7  
9
2.8  
9.2  
2.2  
(2)  
(3)  
ft  
7.2  
7.2  
Maximum solid body size  
mm  
inches  
2.0  
0.08  
2.0  
0.08  
2.0  
0.08  
2.0  
0.08  
Sound pressure equivalent  
50 cycles/min  
(feeding 5 bar)  
(4)  
dB(A)  
dB(A)  
73  
85  
73  
85  
73  
85  
73  
85  
Sound pressure equivalent  
maximum flow rate  
(feeding 8 bar)  
Sound power at maximum  
flow rate (feeding 8 bar)  
Fluid connections  
(inlet & outlet bush)  
Weight  
(4)  
(5)  
dB(A)  
99  
99  
99  
99  
BSP(G)  
1/2"  
1/2"  
1/2"  
1/2"  
kg  
lb  
3.2  
7.1  
3.2  
7.1  
3.2  
7.1  
3.2  
7.1  
20  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Description  
Unit  
Wetted parts materials  
Maximum material  
pressure at the pump's  
inlet  
MPa  
bar  
psi  
0.1  
1
14.5  
Material temperature  
°C  
°F  
°C  
°F  
+4÷60  
+4÷60  
+4÷80  
+4÷80  
+39÷140 +39÷140 +39÷176 +39÷176  
Ambient temperature  
+4 ÷ +40  
+39 ÷ +104  
Allowable sloping position  
for operation  
10°  
(1) PF = Perfect Flow = low pulsation pump with a shorter stroke  
(2) Pump with stainless steel valves (start condition: empty pump / dry valves)  
(3) Pump with plastic valves (start condition: empty pump / dry valves)  
(4) LqA (10s)  
(5) ISO 3744  
WARNING  
Outgoing air containing oil!  
Risk of poisoning if inhaled.  
Air motor switching problems.  
Provide compressed air free from oil and water (quality standard  
5.5.4 according to ISO 8573.1)  
5.5.4 = 40 μm / +7 / 5 mg/m³.  
21  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
5.3.3 DIMENSIONS AND CONNECTIONS  
A
J
B
J
J
J
K
J
J
J
E
F
G
H
B_04007  
S = E + (2 x N)  
Wall mount  
M
N
O
E
P
Q
R
M
B_04028  
22  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Aluminum  
Stainless steel Polypropylene  
Aluminum  
Polypropylene  
and  
Aluminum  
and  
conductive  
Acetal  
conductive  
Acetal  
mm; inch  
200.5; 7.89  
147.5; 5.80  
231.0; 9.09  
184.0; 7.24  
155.0 - 161.0;  
6.10 - 6.34  
86.0; 3.38  
mm; inch  
210.0; 8.27  
147.5; 5.80  
232.5; 9.15  
184.0; 7.24  
157.5 - 163;  
6.20 - 6.42  
86.0; 3.38  
mm; inch  
205.0; 8.07  
149.0; 5.86  
236.0; 9.29  
191.0; 7.52  
154.0 - 162.0  
6.06 - 6.38  
87.0; 3.42  
mm; inch  
200.5; 7.89  
147.5; 5.80  
231.0; 9.09  
184.0; 7.24  
155.0 -161.0;  
6.10 - 6.34  
86.0; 3.38  
mm; inch  
205.0; 8.07  
149.0; 5.86  
236.0; 9.29  
191.0; 7.52  
154.0 - 162.0 ;  
6.06 - 6.38  
87.0; 3.42  
mm; inch  
220.0; 8.66  
174.5; 6.87  
277.5; 10.92  
220.5; 8.68  
168.0 - 174.0;  
6.61 - 6.85  
95.0; 3.74  
192.5; 7.58  
100.0; 3.94  
188; 7.40  
100.0; 3.94  
187.0; 7.36  
101.0; 3.97  
G1/2" (BPS) F  
192.5; 7.58  
100.0; 3.94  
187.0; 7.36  
101.0; 3.97  
205.5; 8.09  
110.0; 4.33  
G3/4" (BPS) F  
R1/4" (BSPT) M  
ø9.0; ø0.35  
37.5; 1.48  
80.0; 3.15  
189; 7.4  
98; 3.85  
83; 3.27  
23  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
5.3.4 PERFORMANCE DIAGRAMS  
Example  
ꢀ BAR  
ꢁ BAR  
ꢂ BAR  
"?ꢃꢃꢄꢃꢅ  
Material flow volume - water l/min <gpm>  
Diagram ZIP52  
bar (MPa)  
<psi>  
nl/min  
<scfm>  
10 (1.0)  
<145>  
750  
<26.9>  
600  
<21.4>  
8.0 (0.8)  
<116>  
A
B
A
B
450  
6.0 (0.6)  
<16.1>  
<87>  
300  
<10.7>  
4.0 (0.4)  
<58>  
C
C
150  
<5.4>  
2.0 (0.2)  
<29>  
0
0
0
10  
20  
30  
40  
50  
60  
l/min  
<2.64> <5.28> <7.92> <10.56> <13.21> <15.85> <gpm>  
Material flow volume - water  
A = 8 bar; 0.8 MPa; 116 psi air pressure  
B = 6 bar; 0.6 MPa; 87 psi air pressure  
C = 4 bar; 0.4 MPa; 58 psi air pressure  
The chart above refers to the aluminium version with stainless steel valves.  
24  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Diagram ZIP52 PF  
bar (MPa)  
<psi>  
nl/min  
<scfm>  
10 (1.0)  
<145>  
250  
<8.9>  
A
200  
<7.1>  
8.0 (0.8)  
<116>  
A
150  
<5.4>  
6.0 (0.6)  
<87>  
B
B
100  
4.0 (0.4)  
<3.6>  
<58>  
C
C
50  
<1.8>  
2.0 (0.2)  
<29>  
0
0
0
5
10  
15  
20  
25  
30  
l/min  
<1.32> <2.64> <3.96> <5.28> <6.60> <7.92> <gpm>  
Material flow volume - water  
A = 8 bar; 0.8 MPa; 116 psi air pressure  
B = 6 bar; 0.6 MPa; 87 psi air pressure  
C = 4 bar; 0.4 MPa; 58 psi air pressure  
The chart above refers to the aluminium version with stainless steel valves.  
Diagram ZIP80  
bar (MPa)  
<psi>  
nl/min  
<scfm>  
10 (1.0)  
<145>  
750  
<26.9>  
A
600  
<21.4>  
8.0 (0.8)  
<116>  
A
450  
<16.1>  
6.0 (0.6)  
<87>  
B
B
300  
4.0 (0.4)  
<10.7>  
<58>  
C
C
150  
<5.4>  
2.0 (0.2)  
<29>  
0
0
0
15  
30  
45  
60  
75  
90  
l/min  
<3.96> <7.92> <11.88> <15.85> <19.80> <23.76> <gpm>  
Material flow volume - water  
A = 8 bar; 0.8 MPa; 116 psi air pressure  
B = 6 bar; 0.6 MPa; 87 psi air pressure  
C = 4 bar; 0.4 MPa; 58 psi air pressure  
The chart above refers to the aluminium version with stainless steel valves.  
25  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
5.4 MODE OF OPERATION  
C
C
B
A
A
P
P
M
M
C
C
B_04006  
Double diaphragm pump - operating principle  
The double diaphragm pump is driven with compressed air.  
Two diaphragms (A) are mechanically connected to each other by means of a shaft (B).  
Each diaphragm generates two chambers: pumping chamber (P) and motor chamber (M).  
A pneumatic distributor alternately supplies compressed air into one of the driving  
chambers (M), thus producing the diaphragms movement and consequently causing one  
of the pumping chambers (P) to empty (as a result of volume decrease), while at the same  
time the other chamber (P) sucks the fluid in (as a result of volume increase). A series of four  
check valves (C) prevents the liquid from flowing back, thus producing the suction and  
delivery phases in each pumping chamber, and generating the pumping effect.  
The ZIP models are equipped with an internal safety valve that opens when the maximum  
allowed value of air pressure supply is exceeded.  
WARNING  
Overpressure!  
Risk of injury from bursting components.  
Never change the safety valve setting.  
26  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
6 ASSEMBLY AND COMMISSIONING  
6.1 TRANSPORTATION  
The pump may be moved manually, without lifts and cranes.  
6.2 STORAGE  
Store the pump in a closed and dry environment.  
Thoroughly clean the pump, if a long-term decommissioning is planned.  
When resuming pump operation, proceed as described in the following sections.  
WARNING  
Discharge of electrostatically charged components in atmospheres  
containing solvents!  
Explosion hazard from electrostatic sparks.  
Clean the pump only with a damp cloth.  
6.3 ASSEMBLY  
Install the pump on a flat and horizontal foundation and screw it on tightly.  
Ensure that all fixing screws (diaphragm covers, manifold, covers) are correctly tightened.  
Tighten the fixing screws regularly depending on pump use. In the case of continuous  
or prolonged operation, it is advisable to check at least once a week that there are no air  
and/or liquid leaks.  
B_04010  
WARNING  
Oblique flooring!  
Risk of accidents if the unit rolls away/falls.  
Place the frame with the pump horizontally.  
Secure frame.  
27  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Material delivery valve  
Material return valve  
Material hose  
Delivery manifold  
Air pressure regulator  
Air cutoff valve  
Suction hose  
Suction manifold  
Air suction filter  
B_04008  
Material connection:  
On the suction manifold of the pump (bottom) connect the suction hose. On the delivery  
manifold (top) connect the material hose. Use flexible hoses to absorb the pump's  
vibrations. Ensure that the hoses are not mechanically stressing the pump. Never connect  
the pump with rigid pipes.  
For pumps installed in areas subject to explosion hazards, all hoses and pipes must be  
made of conductive material and must be grounded.  
Install a suction filter on the suction hose. This prevents particles, that are large enough to  
damage the internal parts of the pump, from entering. Refer to the paragraph Technical  
Data to verify the maximum size of solids that can be pumped.  
28  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
All hoses and components connected to the supply line must be able to operate at the  
pump’s maximum pressure with the pump working at a pulsating pressure.  
All items connected to the suction manifold must not get crushed as a result of the  
depression produced by the pump.  
The suction and delivery hoses and pipes must have a cross-section proportionate to the  
flow rate and the viscosity of the pumped fluid. Avoid long and winding pipes, especially  
in the suction.  
B_04011  
Air inlet connection:  
The driving air pipe must be properly dimensioned.  
Connect the compressed air supply to the pump to the pressure distribution network.  
The connection must be carried out on the fitting on the pump. Do not replace the  
original connection.  
Use a pipe with a suitable diameter for the connection.  
Always install an air cutoff valve and an air processing unit (filter/regulator unit).  
The pressure must not exceed the maximum value indicated on the plate.  
Air pressure quality:  
The pneumatic motor must be supplied with clean and dry industrial air. Make sure efficient  
filter and condensation separation systems are installed on the air line.  
The pump can run with non-lubricated air.  
Air pressure quality: 5.5.4 = 40 μm / +7 / 5 mg/m³  
Reversing valve:  
The reversing valve of the pump is lubricated at the factory and does not need any  
lubrication.  
Safety valve:  
The ZIP models are equipped with an internal safety valve that opens when the maximum  
allowed value of air pressure supply is exceeded.  
Back-pressure valve:  
If the pump has been installed on a higher level than the liquid to be pumped, it is  
recommended that a back-pressure valve be provided at the lower end of the suction pipe.  
29  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
6.4 GROUNDING (EXCEPT FOR NON-CONDUCTIVE PLASTIC UNITS)  
WARNING  
Discharge of electrostatically charged components in atmospheres  
containing solvents!  
Explosion hazard from electrostatic sparks.  
Clean the pump only with a damp cloth.  
WARNING  
Heavy paint mist if grounding is insufficient!  
Danger of poisoning.  
Insufficient paint application quality.  
Ground all device components.  
Ground the work pieces to be coated.  
Grounding schema (example)  
Conveyor  
Spraying stand  
Work piece  
R max < 1 MΩ  
Paint container  
B_00304  
Electrostatically conductive flooring  
30  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
The ground connection is at the pumps of metal and conductive acetal imperative.  
Note: Pump of nonconductive plastic have no ground connection.  
B_04001  
Procedure:  
1. Remove the crimp connection delivered with the pump.  
2. Crimp the grounding cable on the terminal and screw it back onto the pump’s foot.  
3. Ground the material/paint container to a local ground connection.  
4. Ground the other parts of the system to a local ground connection.  
31  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
6.5 COMMISSIONING  
6.5.1 SAFETY REGULATIONS  
Every time before starting up the following points should be observed as laid down in  
the operating instructions:  
-
-
Observe all safety regulations in accordance with chapter 4.  
Carry out commissioning properly.  
WARNING  
High pressure spray jet!  
Danger to life from injecting paint or solvent.  
Never reach into the spray jet.  
Never point the spray gun at people.  
Consult a 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 them.  
WARNING  
Toxic and/or flammable vapor mixtures!  
Risk of poisoning and burns.  
Operate the unit in a spray booth approved for the working  
materials.  
-or-  
Operate the unit on an appropriate spraying wall with the  
ventilation (extraction) switched on.  
Observe national and local regulations for the outgoing air  
speed.  
WARNING  
Gas mixtures can explode if there is an incompletely filled pump!  
Danger to life from flying parts.  
Ensure that the pump and suction system are always completely  
filled with cleaning agent or working medium.  
Do not spray the unit empty after cleaning.  
Emergency stop  
In the case of unforeseen occurrences close the air cut-off valve immediately and open the  
return valve (if installed) and/or delivery devices (valves or guns).  
32  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
6.5.2 PRELIMINARY OPERATIONS  
Preliminary flushing  
The pump was tested with oil or other fluids, depending on the model.  
Before use, it is necessary to wash the pump once using an adequate solvent.  
Ensure that:  
-
-
-
The pressure regulator knob is turned fully counterclockwise (0 bar pressure).  
The air cutoff valve is closed.  
The material delivery valve and the return valve, if installed, are opened.  
Delivery  
Opened  
Opened  
Discharge  
(Return line)  
Closed  
Air  
B_04012  
Open the air cutoff valve and turn the regulator knob clockwise until the pump starts.  
Opened  
Delivery  
Opened  
Discharge  
(Return line)  
Opened  
Air  
B_04013  
Start-up problems:  
If the pump doesn't start up, carry out the following steps:  
Close the air cutoff valve.  
Turn the regulator knob of the air pressure regulator off counterclockwise (0 bar pressure).  
Open the air cutoff valve for air.  
Turn the regulator knob clockwise until the pump starts.  
If necessary, repeat the operation several times.  
While the pump is priming, don’t exceed with the speed.  
33  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Close the return valve, if installed.  
Delivery  
Opened  
Closed  
Discharge  
(Return line)  
Opened  
Air  
B_04014  
Let the solvent flow through the pump for 2 or 3 minutes.  
6.5.3 UNIT PRESSURE TIGHTNESS TEST  
Close the material delivery valve, once the pump is primed.  
Gradually increase the pressure until reaching the maximum allowed value for the pump  
and the devices connected to it. Ensure that the fittings do not leak.  
34  
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VERSION 12/2012  
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OPERATING MANUAL  
7 OPERATION  
7.1 OPERATION  
Suction:  
Make sure that the air pressure regulator knob is turned fully counterclockwise (0 bar  
pressure).  
Open the compressed air and material delivery valve, then increase the air pressure until  
the pump starts. While the pump is priming, don’t exceed with the speed.  
Return valve:  
To facilitate the priming of the pump, open the return valve, if installed.  
The return valve is strongly recommended in case of viscous materials or long pipes. Close  
the return valve when the suction is finish.  
Material delivery:  
The pump supplies the material while the material delivery valve is open.  
Change the air pressure with the air pressure regulator, in order to achieve the desired  
amount respectively pressure of material.  
Drawn in air:  
In case air accidentally flows into the pump suction inlet, it is necessary to immediately  
reduce the compressed air pressure to avoid the pump working at an excessive speed.  
Stopping the pump:  
To stop the pump, simply close the material delivery valve or any other device installed  
(such as dispensing valves or guns) on the delivery line.  
7.2 ENDING WORK  
At the end of the Work close the air cutoff valve. Relieve the pressure in the material line, by  
opening the return valve (if installed) or the dispensing device (valve or spray gun).  
Dealing with hardening liquids:  
In case of hardening liquids such as 2-component mixed resins, the pump, and anything  
connected to it, must be thoroughly flushed out at the end of working session with using a  
solvent suitable for the type of resin being used. The solvent must be left inside the pump,  
until its next use.  
7.3 STORAGE OVER 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. Use a suitable preserving fluid, according to the material of  
the wetted parts of the pump.  
35  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
8 TROUBLE SHOOTING AND PROBLEM SOLVING  
Problem  
Cause  
Remedy  
The pump does not  
work.  
The air motor does not work or  
stops.  
Close the air cutoff valve, increase the  
pressure and open the air cutoff valve  
immediately.  
No pressure indication  
(pressure regulator defective).  
The delivery line is clogged.  
Insufficient supply of compressed  
air.  
Disconnect compressed air supply briefly or  
repair or replace the pressure regulator.  
Check the delivery line.  
Check the compressed air supply.  
The filter in delivery line is clogged Clean or replace the filter.  
(if installed).  
The unit is working (i.e.: The suction filter is clogged  
Carefully clean the filter.  
the pump is moving),  
(if installed).  
but no fluid is delivered.  
No fluid is available at the pump’s  
inlet.  
Check the fluid level in the tank or  
container.  
The suction pipe is clogged or  
Check the suction pipe. Replace it if  
leaking (possibility of sucking air in necessary.  
from the atmosphere).  
The material flow is  
suspended.  
The suction pipe is partially  
clogged.  
Check the suction pipe. Replace it if  
necessary.  
Cavitation  
Check the suction in the tank. Exclude air  
intake due to high viscosity.  
Check for impurities on the valve seats.  
Replace the check valves if necessary.  
(air bubbles in the liquid).  
The material check valve doesn't  
completely close.  
The pump supply  
Partial clogging of the delivery line. Check the delivery line.  
decreases during work.  
Deviations of the material  
characteristics (like viscosity).  
Ice formation inside the air outlet  
pipes.  
Check the material characteristics.  
Check the compressed air quality.  
Install a condensation separator on the air  
line.  
Install an air dryer if necessary.  
Fill one lubricant with special de-icing fluid.  
The pump supply  
decreases during work, are worn-out.  
and tends to stop  
The delivery manifold valves guides Replace the delivery manifold (or in the case  
of plastic pumps, replace the insert).  
completely.  
36  
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VERSION 12/2012  
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OPERATING MANUAL  
Problem  
Cause  
Remedy  
The material delivery  
valve is closed,  
nevertheless the pump  
continues to run even  
if the supply's air cutoff  
vale is closed.  
The material delivery valve or the  
delivery manifold leaks.  
Dirty or worn-out material check  
valves in the delivery and suction  
manifold.  
Check the material delivery valve and the  
seals of the delivery manifold.  
Clean the check valves and replace them if  
they are worn.  
If the problem is not listed above consult your WAGNER Service Center.  
37  
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VERSION 12/2012  
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OPERATING MANUAL  
9 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 Catalogue" and that are assigned to the unit.  
Before all work on the unit and in the event of work interruptions:  
- 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.  
1. Check and clean the delivery and suction filters daily or as necessary.  
2. Carry out every shut down as explained in paragraph 7.2.  
3. As necessary, check and replace hoses, pipes, and connections daily.  
In accordance with the guideline for liquid emitters (ZH 1/406 and BGR 500 Part 2  
Chapter 2.3):  
- The liquid emitters should be checked by an expert (e.g. Wagner service technician)  
for their safe working conditions as required and at least every 12 months.  
- For shut down devices, the examination can be suspended until the next start-up.  
38  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
9.1 SAFETY INSTRUCTIONS  
Prior to maintenance and cleaning measures note:  
Wear protective clothing and use specific protection devices with regard to the nature of the fluids  
involved.  
Close the compressed air supply and release the pressure from the pump and pipes connected to it.  
Depending on the operation, disconnect the material and air side connection pipes.  
Remove the pump from the base or support it is fastened to.Turn the pump upside-down over a container  
suitable for collecting any liquid it may contain.  
After the pump has been reassembled and reinstalled following maintenance operations:  
check the efficiency of the grounding connection of the individual parts of the pump.  
Carry out pressure retention test in accordance with chapter 6.5.3. Check that no air flows out.  
Note: All threads are right-hand threads.  
9.2 DIAPHRAGM REPLACEMENT (PREVENTIVE MAINTENANCE)  
Mark the coupled parts (Diaphragm covers, distributor, covers) with a felt-tip  
pen so as to make subsequent reassembly easier.  
a) Remove the suction and delivery manifolds.  
b) Disassemble the fastening nuts and remove the outer diaphragm  
covers. Disassemble the pressure side cover (1).  
1
B_04015  
B_04066  
39  
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VERSION 12/2012  
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OPERATING MANUAL  
c) Hald the end nut of an outer diphragm disk with a wrench. Loose the end nut of the other diaphragm  
disk and remove.  
d) Remove the freed diaphragm with its corresponding internal disc, and remove the shaft from the motor  
block.  
12 Nm  
8.8 lbft  
B_04067  
e) Lock the end of the shaft released from the diaphragm in a bench vice (provide soft jaws to avoid  
damaging it) and disassemble the external diaphragm disc from the opposite end of the shaft. Then  
remove the second diaphragm with its internal disk.  
f) Assemble the new diaphragm with its internal disc and properly fasten it to the relevant external disc.  
g) Remove the shaft from the bench vice and put it in the motor block. Grease the shaft inside and outside  
(beyond the underside of the motor block. Thereby move the shaft in different positions. See chapter 11.  
h) Mount the inner diaphragm disc, the diaphragm and the outer disc and tighten them properly onto the  
nut of the opposite outer discs using two wrenches.  
i) Attach the noise reduction and the pressure side cover. Check the correct positioning of the cover and  
its seal.  
k) Attach the outer diaphragm cover and the manifolds. Ensure correct position of seals of the ball valves  
when doing so.  
l) Screw on and tighten the cover screws. Tighten the manifold screws. To the directions in chapter 11 apply  
the right torque.  
40  
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VERSION 12/2012  
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OPERATING MANUAL  
9.3 DIAPHRAGM REPLACEMENT (DUE TO BREAKAGE)  
If the diaphragms are replaced as a result of breakage,  
all the internal parts of the motor must be cleaned and  
the condition of the seals and reversing valve, which  
may have been damaged by contact with the pump  
fluid, must be checked.  
3.5 Nm  
2.6 lbft  
a) According to chapter 9.2, points a), b), c) d) and e):  
Followthedisassemblyprocedureofthediaphragms.  
b) Disassemble the reversing valve (2).  
1
c) Remove the shaft's plastic bushings (3) located at  
each end of the motor block, the lip seals (4) and  
the feeler pins (5).  
2 Nm; 1.5 lbft  
2
d) Clean all the components, openings and spaces  
within the motor block. Blow the housing cavity  
of the reversing valve out thoroughly with a jet of  
compressed air (wear safety goggles).  
e) Check the condition of the reversing valve. If  
necessary replace.  
6
5
4
3
2 Nm  
1.5 lbft  
B_04018  
f) Grease feeler pins (5) (see chapter 11).  
g) Assemble all the parts described under point c) paying attention to properly orient the seals lips (see  
chapter 11, exploded view).  
h) Grease feeler pins (5) with lip seal (4) once more from outside  
i) Put the reversing valve back in its housing. There apply the right torque. Mount the valve slider (6) on one  
of the stroke stop positions. There are four possible positions, each of them is suitable.  
k) According to chapter 9.2, points f), g), h), i), k) and l):  
Reassemble the remaining components.  
9.4 CLEANING / REPLACEMENT OF THE SUCTION AND DELIVERY BALL VALVES  
a) Remove the suction and delivery manifold.  
b) Remove the gaskets, seats and balls from the diaphragm covers and the housings of the manifolds.  
c) Check the condition of wear of the ball guide/stops inside the diaphragm covers and manifolds. Replace  
if worn.  
d) Remove all dirt particles as well as hardened material residues. Check the ball and seats for excessive  
wear. Clean or replace the components.  
e) Clean the contact surfaces of the manifolds and the diaphragm covers and assemble the components. To  
the directions in chapter 11 apply the right torque.  
It is recommended that the static seals be replaced when reassembling.  
41  
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VERSION 12/2012  
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OPERATING MANUAL  
9.5 REPLACEMENT OF THE REVERSING VALVE  
a) Disassemble the pressure side cover and remove the reversing valve.  
b) To clean it, blow the housing cavity of the reversing valve out with a jet of compressed air (wear safety  
goggles).  
c) Put the new reversing valve in its housing. There apply the right torque (see picture in chapter 9.3).  
Mount the valve slider (6) on one of the stroke stop positions. There are four possible positions, each of  
them is suitable. Attach the pressure side cover.  
During the performance of the operations described above, check the positioning of the valve‘s seals and  
cover including the seal. To the directions in chapter 11 apply the right torque.  
9.6 MATERIAL HOSES  
The lifetime of the fluid hoses is, even with appropriate handling, reduced due to environmental influences.  
Check pipes, tubes, and couplings every day and replace if necessary.  
As a precaution fluid hoses should be replaced after a period specified by the plant operator.  
WARNING  
Bursting hose, bursting threaded joints!  
Danger to life from injection of material.  
Ensure that the hose material is chemically resistant to the  
sprayed materials.  
Ensure that the spray gun, threaded joints and material hose  
between the unit and the spray gun are suitable for the pressure  
generated in the unit.  
9.7 DECOMMISIONING  
When the equipment must be scrapped, please differentiate the disposal of the waste  
materials. The following materials have been used:  
Steel  
Aluminum  
Elastomerics  
Plastics  
Carbide  
The consumable materials (paints, adhesives, sealers, solvents) must be disposed of  
according to the valid specific standards.  
42  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
10 ACCESSORIES  
11  
12  
2
12  
11  
13  
3
1
10  
9
6
7
8
5
B_04029  
4
Accessory list  
Order No. Description  
-- ZIP pump  
P123.00 Pressure regulator  
1
2
3
9998677 Pressure gauge  
4
T760.00M Wall mount  
5
6
T406.00 Suction hose stainless steel assy.  
H401.07 Filter support disc  
7
T453.03 Suction hose filter  
8
9
H206.03 Suction hose spring  
S402.06A Solvent resistant suction hose  
T420.00 Suction pipe stainless steel  
E0107.03 Contact clip stainless steel  
R601.00 Hose clamp  
10  
11  
12  
13  
13  
B274.03 Hose fitting - stainless steel  
M208.04 Hose fitting - nickel coated brass  
43  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Connections configurations  
B_04061  
B_04020  
LEFT / LEFT  
U55x.xxxx1  
UNIVERSAL / UNIVERSAL  
U55x.xxxx7  
U551.303  
B_04021  
INDEPENDENT / INDEPENDENT  
U55x.xxxx8  
44  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
11 SPARE PARTS  
11.1 HOW CAN SPARE PARTS BE ORDERED?  
Always supply the following information to ensure delivery of the right spare part:  
Order number, designation and quantity  
The quantity need not be the same as the number given in the quantity column " " on  
the list. This number merely indicates how many of the respective parts are used in each  
module.  
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 (normal mail, express delivery, air freight, courier)  
Identification in spare parts lists  
Explanation of column " " (labeling) in the following spare parts lists:  
Wearing part  
Note: No liability is assumed for wearing parts.  
Not part of standard equipment, available, however, as additional extra.  
WARNING  
Incorrect maintenance/repair!  
Risk of injury and damage to the device.  
Have repairs and part replacements carried out by specially  
trained staff or a WAGNER service center.  
Before all work on the unit and in the event of work interruptions:  
- 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.  
45  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
11.2 ZIP52 PUMP - METAL - UNIVERSAL CONNECTIONS  
5 Nm; 3.7 lbft  
25  
15  
8
2
2
15  
(U551.303)  
13  
25  
26  
19  
21  
16  
6
14  
5
12 Nm; 8.8 lbft  
5 Nm; 3.7 lbft  
22  
23  
24  
17  
10  
3
12  
18  
4
1
20  
15  
5 Nm; 3.7 lbft  
11  
9
25  
7
B_04022  
46  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Zip52 metal - universal  
Order No. Order No. Order No. Order No. Order No. Description  
1
1
1
2
2
2
2
4
4
4
12  
8
20  
1
2
12  
4
1
4
1
U550.ATRD7 U550.ATSS7 U550.STSS7 U551.303 U551.ATSS7 DDP ZIP  
1
2
3
4
5
6
7
8
8
F184.01C  
F185.01C  
F834.07R  
F978.01  
G921.05  
G921.06  
K142.62  
K183.62  
--  
K311.62  
9910204  
9920103  
K1012.62  
K1041.62  
K1044.62  
F184.01C  
F185.01C  
F834.07R  
F978.01  
G921.05  
G921.06  
K142.62  
K183.62  
--  
K311.62  
9910204  
9920103  
K1012.62  
K1041.62  
K1044.62  
F188.03C F184.01C F184.01C Suction manifold  
F189.03C T6133.00 F185.01C Delivery manifold  
F834.07R F834.07R F834.07R Outer diaphragm disc  
F192.03  
G921.05  
G921.06  
K142.62  
--  
K142.62  
K311.62  
9910204  
9920103  
F978.01  
G921.05  
G921.06  
K142.62  
K183.62  
--  
K311.62  
9910204  
9920103  
F978.01 Diaphragm cover  
G921.05 Material diaphragm  
G921.06 Support diaphragm  
K142.62 Screw M6x35  
K183.62 Screw M6x30  
--  
Screw M6x35  
9
K311.62 Nut M6  
9910204 Nut M6  
9920103 Washer 6  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
K1012.62 K1012.62 K1012.62 Screw  
K1041.62 K1041.62 K1041.62 Rivet  
K1044.62 K1044.62 K1044.62 Screw  
M254.14A M254.14A M811.03B M254.14A M254.14A Plug 1/2  
T6103.00  
T6105.00C  
Y622.00A  
--  
T6103.00  
T6105.00  
Y622.00A  
--  
T6103.00 T6103.00S T6103.00S Motor  
T6105.00 T6105.00 T6105.00 Valve-unit  
Y622.00A Y622.00A Y622.00A Cable lug  
1
2
1
4
4
4
1
1
--  
--  
--  
--  
--  
--  
Coverplate  
Cover round plate  
--  
--  
B0177.14  
K805.07D  
B0177.14  
K805.03  
B0177.14 B0177.14A B0177.14A Nipples  
K805.03 K805.03 K805.03 Ball  
B0148.07R B0148.03A B0148.03A B0148.03A B0148.03A Ball seat  
L206.05  
3201587  
9992831  
L206.05  
3201587  
9992831  
L206.05  
3201587  
9992831  
L206.05  
3201587  
9992831  
L206.05 O-ring  
3201587 Loctite 577  
9992831 Loctite 542  
Wearing part  
included in service set  
included in product’s o-ring set  
47  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
11.3 ZIP52 PUMP - METAL - INDEPENDENT CONNECTIONS  
5 Nm; 3.7 lbft  
8
2
2
22  
23  
17  
25  
13  
19  
24  
21  
14  
16  
6
5
12 Nm; 8.8 lbft  
5 Nm; 3.7 lbft  
10  
12  
18  
3
1
4
20  
1
5 Nm; 3.7 lbft  
11  
9
7
B_04023  
48  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
ZIP52 metallic - independent  
Order No. Description  
U550.ATSS8 DDP ZIP52  
1
2
2
2
2
2
2
4
4
12  
8
20  
1
1
2
3
4
5
6
7
8
F184.01D  
F185.01D  
F834.07R  
F978.01  
G921.05  
G921.06  
K142.62  
K183.62  
K311.62  
9910204  
9920103  
K1012.62  
K1041.62  
K1044.62  
--  
Suction manifold  
Delivery manifold  
Outer diaphragm disc  
Diaphragm cover  
Material diaphragm  
Support diaphragm  
Screw M6x35  
Screw M6x30  
Nut M6  
Nut M6  
Washer 6  
Self-tapping screw  
Rivet  
Screw  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
2
12  
--  
1
4
1
1
2
1
4
--  
T6103.00  
T6105.00  
Y622.00A  
--  
Motor  
Valve-unit  
Cable lug  
Coverplate  
Cover round plate  
Nipples  
- -  
B0177.14  
K805.03  
Ball  
4
4
1
B0148.03A Ball seat  
L206.05  
O-ring  
9992831  
Loctite 542  
Wearing part  
included in service set  
included in product’s o-ring set  
49  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
11.4 ZIP52 PUMP - CONDUCTIVE ACETAL  
4.5 Nm; 3.3 lbft  
8
27  
15  
2
2
(U55x.xxxx7)  
(U55x.xxxx1)  
15  
22  
27  
17  
13  
19  
26  
23  
24  
25  
21  
16  
6
14  
5
12 Nm; 8.8 lbft  
7 Nm; 5.2 lbft  
3
12  
28  
18  
4
20  
15  
(U55x.xxxx7)  
27  
1
11  
9
10  
7
B_04062  
4.5 Nm; 3.3 lbft  
(U55x.xxxx1)  
1
50  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
ZIP52 Conductive Acetal  
U552.GHSS1 U552.GHSS7 U553.GTSS1  
Order No. Order No. Order No. Description  
U552.GHSS1 U552.GHSS7 U553.GTSS1 DDP ZIP52  
1
1
1
1
1
2
2
2
2
4
4
20  
4
16  
1
2
12  
4
1
4
1
1
2
2
3
4
5
6
7
--  
F1017.07G-C  
--  
F1016.07G-C  
--  
F834.07D  
F831.07G-A  
G921.07B  
--  
K128.62  
K1076.62  
K311.62  
9920103  
K508.62  
K1012.62  
K1041.62  
K1043.62  
M052.08  
T6103.00  
T6105.00  
Y622.00A  
--  
--  
Suction manifold - universal  
F833.07G-A  
--  
F833.07G-A Suction manifold - left  
--  
Delivery manifold - universal  
Delivery manifold - left  
Extern diaphragm disc  
F859.07G  
F834.07D  
F831.07G-A  
G921.07B  
--  
K128.62  
K1076.62  
K311.62  
9920103  
K508.62  
K1012.62  
K1041.62  
K1043.62  
--  
F859.07G  
F834.07D  
F831.07G-A Diaphragm cover conductive  
G921.05  
G921.06  
K128.62  
K1076.62  
K311.62  
9920103  
K508.62  
K1012.62  
K1041.62  
K1043.62  
--  
Diaphragm  
Support diaphragm  
Screw M6x40  
Screw M6x75  
Nut M6  
Washer 6  
Washer 6x18  
Screw  
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
Rivet  
Screw  
Plug 1/2"  
T6103.00  
T6105.00  
Y622.00A  
--  
T6103.00S Motor  
T6105.00  
Y622.00A  
Valve-unit  
Cable lug  
Coverplate  
1
1
2
--  
--  
--  
--  
Cover round plate  
1
4
4
4
2
1
1
1
B0177.14  
K805.03  
B0148.03A  
L206.05  
F856.07D  
9992831  
--  
B0177.14  
K805.03  
B0148.03A  
L206.05  
F856.07D  
9992831  
3051530  
K558.62  
B0177.14A Nipples  
K805.03 Ball 3/4"  
B0148.03A Seat  
L206.05  
F856.07D  
9992831  
--  
O-ring  
Ball guide  
Loctite 542  
PTFE tape  
Washer  
K558.62  
K558.62  
Wearing part  
included in service set  
included in product’s o-ring set  
51  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
11.45 ZIP52 PUMP - POLYPROPYLENE - UNIVERSAL CONNECTIONS  
5 Nm; 3.7 lbft  
8
27  
15  
2
15  
22  
27  
17  
13  
19  
26  
23  
24  
25  
21  
16  
6
14  
5
12 Nm; 8.8 lbft  
7 Nm; 5.2 lbft  
3
20  
4
15  
27  
10  
1
11  
9
5 Nm; 3.7 lbft  
7
B_04024  
52  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
ZIP52 polypropylene - universal  
Order No.  
Order No.  
Order No. Description  
1
1
1
U552.PTSS7 U553.PHSD7 U553.PTSS7 DDP ZIP52  
F1017.07P-C F1017.07P-C F1017.07P-C Suction manifold  
F1016.07P-C F1016.07P-C F1016.07P-C Delivery manifold  
1
2
3
4
5
6
7
8
9
2
2
2
2
4
4
20  
4
16  
--  
2
12  
4
1
4
--  
1
2
1
F834.07P  
F831.07P-A  
G921.05  
G921.06  
K128.62  
K1076.62  
K311.62  
9920103  
K508.62  
--  
K1041.62  
K1043.62  
M052.08  
T6103.00  
T6105.00  
--  
F834.07P  
F831.07P-A  
G921.07B  
--  
K128.62  
K1076.62  
K311.62  
9920103  
K508.62  
--  
K1041.62  
K1043.62  
M052.08  
T6103.00S  
T6105.00I  
--  
F834.07P  
F831.07P-A Diaphragm cover  
Outer diaphragm disc  
G921.05  
G921.06  
K128.62  
K1076.62  
K311.62  
9920103  
K508.62  
--  
K1041.62  
K1043.62  
M052.08  
T6103.00S Motor  
T6105.00  
Material diaphragm  
Support diaphragm  
Screw M6x40  
Screw M6x75  
Nut M6  
Washer 6  
Washer 6x18  
--  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
Rivet  
Screw  
Plug 1/2  
Valve-unit  
--  
Coverplate  
Cover round plate  
--  
--  
--  
--  
--  
--  
--  
B0177.14  
K805.03  
B0148.03A  
L206.05  
F856.07P  
9992831  
3051530  
B0177.14A  
K805.07D  
B0148.03A  
L206.05  
F856.07P  
9992831  
3051530  
B0177.14A Nipples  
K805.03 Ball  
B0148.03A Ball seat  
L206.05  
F856.07P  
9992831  
3051530  
4
4
4
2
1
1
O-ring  
Ball’s guide insert  
Loctite 542  
PTFE tape  
Wearing part  
included in service set  
included in product’s o-ring set  
53  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
11.6 ZIP80 PUMP - ALUMINUM - UNIVERSAL CONNECTIONS  
27  
15  
5 Nm; 3.7 lbft  
8
25  
2
15  
13  
27  
28  
19  
21  
16  
14  
5
12 Nm; 8.8 lbft  
5.5 Nm; 4.06 lbft  
10  
12  
26  
3
18  
20  
22  
23  
24  
4
17  
1
15  
11  
9
15  
27  
5 Nm; 3.7 lbft  
B_04026  
7
54  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Zip 80 aluminum - universal  
Order No. Description  
U555.ATSS7 DDP ZIP80  
1
1
1
2
2
1
2
3
4
F186.01C  
F187.01C  
F838.07R  
F981.01  
Suction manifold  
Delivery manifold  
Outer diaphragm disc  
Diaphragm cover  
5
2
G922.07AB Diaphragm  
6
7
8
9
--  
4
4
12  
12  
12  
1
2
12  
4
1
4
1
1
2
1
4
4
4
8
--  
--  
K128.62  
K142.62  
9910208  
K311.62  
9920102  
K1057.62  
K1041.62  
K1053.62  
M405.24  
T6104.00  
T6106.00  
Y622.00A  
--  
Screw M6x40  
Screw M6x35  
Nut M8  
Nut M6  
Washer 8  
Screw  
Rivet  
Screw  
Plug 3/4  
Motor  
Valve-unit  
Cable lug  
Coverplate  
Cover round plate  
Nipples  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
--  
B0177.14  
K803.03  
B0149.03A Ball seat  
L208.05  
9920103  
K558.62  
3201587  
9992831  
Ball  
O-ring  
Washer 6  
Washer  
Loctite 577  
Loctite 542  
1
1
1
Wearing part  
included in service set  
included in product’s o-ring set  
55  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
11.7 ZIP MOTOR  
3.5 Nm; 2.6 lbft  
20  
19  
21  
4
21  
9
1
3
2 Nm;  
1.5 lbft  
11  
1
21  
15  
3
8
3
1
13  
21  
14  
2 Nm; 1.5 lbft  
5
17  
12  
2
7
16  
10  
6
18  
B_04027  
56  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
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 Catalogue" and that are assigned to the unit.  
Before all work on the unit and in the event of work interruptions:  
- 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.  
ZIP motor  
Order No.  
T6103.00  
B0146.04  
B0147.71  
B0150.03  
F194.91  
Order No.  
T6103.00S  
B0146.04  
B0147.71  
B0150.03S  
F194.91  
Order No. Description  
1
2
2
1
1
2
1
1
1
1
1
4
6
2
2
1
1
1
4
4
4
T6104.00  
B0146.04  
B0151.71  
B0150.03  
F194.91  
F829.07  
F830.07  
Motor  
Feeler pin  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
Inner diaphragm disc  
Shaft  
Cover (pressure side)  
Shaft guide bushing  
Cover (exhaust side)  
F829.07  
F830.07  
F829.07  
F830.07  
T6103.00A  
G925.06  
G7020.06  
H618.07  
K1038.62  
K1039.62  
L470.06  
T6103.00A  
G925.06  
G7020.06  
H618.07  
K1038.62  
K1039.62  
L470.06  
T6104.00A Motor block with safety valve  
G925.06 Reversing valve gasket  
G7020.06 Pressure cover gasket  
H618.07  
K1038.62  
K1039.62  
L470.06  
Noise reduction  
Screw  
Screw  
Lip seal  
L471.06  
L471.06  
L471.06  
Lip seal  
P4003.00  
See pos. 7.  
Z546.C0  
K1040.62  
3155401  
K311.62  
P4003.00  
See pos. 7.  
Z546.C0  
K1040.62  
3155401  
K311.62  
P4003.00  
Reversing valve (*)  
See pos. 7. Safety valve (**)  
Z546.C0B Side label  
K1040.62  
3155401  
K311.62  
Z125.00  
Screw  
Contact washer  
Self-locking nut M6  
High-performance grease  
Z125.00  
Z125.00  
(*) Includes pos. 8 and 9.  
Not available separately  
(**)  
Wearing part  
included in pump's service set  
57  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
11.8 SERVICE SETS  
Pump No. Diaphragm Valve seat  
Valve ball  
Acetal (POM)  
Service set  
T9080.00A  
T9080.00  
T9080.00  
T9080.00  
T9080.00  
T9080.00  
O-ring set  
T9077.00  
T9077.00  
T9077.00  
T9077.00  
T9077.00  
T9077.00  
T9077.00  
T9077.00  
T9077.00  
T9077.00  
T9077.00  
T9077.00  
T9084.00  
Air valve set  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
P4003.00  
U550.ATRD7  
U550.ATSS7  
U550.ATSS8  
U550.STSS7  
U551.ATSS7  
U551.303  
PTFE  
PTFE  
PTFE  
PTFE  
PTFE  
PTFE  
PPS  
Stainless steel Stainless steel  
Stainless steel Stainless steel  
Stainless steel Stainless steel  
Stainless steel Stainless steel  
Stainless steel Stainless steel  
U552.GHSS1  
U552.GHSS7  
U552.PTSS7  
U553.GTSS1  
U553.PHSD7  
U553.PTSS7  
U555.ATSS7  
UHMWPE Stainless steel Stainless steel T9080.00B  
UHMWPE Stainless steel Stainless steel T9080.00B  
PTFE  
PTFE  
Stainless steel Stainless steel  
Stainless steel Stainless steel T9080.00B  
T9080.00  
UHMWPE Stainless steel Acetal (POM)  
T9080.00G  
T9080.00  
T9085.00  
PTFE  
PTFE  
Stainless steel Stainless steel  
Stainless steel Stainless steel  
Service set consists of: see parts list  
O-Ring set consists of:  
4 O-rings for the valve units (material check valves)  
Air valve set consists of:  
1 Reversing valve  
1 Reversing valve seals  
1 Pressure cover seals  
58  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
12 GUARANTEE AND CONFORMITY DECLARATIONS  
12.1 IMPORTANT NOTES REGARDING PRODUCT LIABILITY  
As a result of an EC regulation effective from January 1, 1990, the manufacturer shall only  
be liable for his product if all parts originate from him or are approved by him, and if the  
devices are properly mounted, operated and maintained.  
The manufacturer will not be held liable or will only be held partially liable if third-party  
accessories or spare parts have been used.  
With genuine WAGNER accessories and spare parts, you have the guarantee that all safety  
regulations are complied with.  
12.2 GUARANTEE CLAIM  
Full warranty is provided for this device:  
We will at our discretion repair or replace free of charge all parts which within 36 months  
in single-shift, 18 months in double-shift or 9 months in triple-shift operation from date of  
receipt by the purchaser are found to be wholly or substantially unusable due to causes  
prior to the sale, in particular faulty design, defective materials or poor workmanship.  
The type of warranty provided is such that the device or individual components of the  
device are either replaced or repaired as we see fit. The resulting costs, in particular  
shipping charges, road tolls, labour and material costs will be borne by us except where  
these costs are increased due to the subsequent shipment of the unit to a location other  
than the address of the purchaser.  
We do not provide warranty for damage that has been caused or contributed to for the  
following reasons:  
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a  
third party, normal wear, negligent handling, defective maintenance, unsuitable coating  
products, substitute materials and the action of chemical, electrochemical or electrical  
agents, except when the damage is attributable to us.  
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc  
dust paints and so forth reduce the service life of valves, packaging, spray guns, nozzles,  
cylinders, pistons etc. Wear and tear due to such causes are not covered by this guarantee.  
Components that have not been manufactured by WAGNER are subject to the original  
warranty of the manufacturer.  
Replacement of a component does not extend the period of warranty of the device.  
The unit should be inspected immediately upon receipt. To avoid losing the warranty, we  
or the supplier company are to be informed in writing about obvious faults within 14 days  
upon receipt of the device.  
We reserve the right to have the warranty compliance met by a contracting company.  
The services provided by this warranty are dependent on evidence being provided in the  
form of an invoice or delivery note. If the examination discovers that no warranty claim  
exists, the costs of repairs are charged to the purchaser.  
It is clearly stipulated that this warranty claim does not represent any constraint on statutory  
regulations or regulations agreed to contractually in our general terms and conditions.  
J. Wagner AG  
59  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
12.3 CE DECLARATION OF CONFORMITY  
Metallic versions (aluminum and stainless steel) and conductive Acetal  
Herewith we declare that the supplied version of the Pneumatic Double Diaphragm Pumps  
with ordner no.  
U550.ATRD7  
U550.ATSS7  
U550.ATSS8  
U550.STSS7  
U552.GHSS1  
U552.GHSS7  
U551.ATSS7  
U551.303  
U553.GTSS1  
U555.ATSS7  
complies with the following guidelines:  
2006/42/EC  
94/9/EC Atex directive  
Applied standards, in particular:  
DIN EN ISO 12100: 2011  
DIN EN ISO 4414: 2011  
DIN EN ISO 13463-1: 2009  
DIN EN 809: 2012  
DIN EN 12621: 2011  
DIN EN ISO 13732-1: 2008  
DIN EN ISO 4413: 2011  
DIN EN 1127-1: 2011  
DIN EN 14462: 2010  
Applied national technical standards and specifications, in particular:  
BGR 500 part 2 chapter 2.29 and chapter 2.36  
TRBS 2153  
Identification:  
II 2G IIB T4 +4°C Tamb +40°C  
CE Certificate of Conformity  
The CE certificate of conformity is enclosed with this product. If needed, further copies  
can be ordered through your WAGNER dealer by specifying the product name and serial  
number.  
Order number:  
2334618  
60  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Non-metallic versions (Non-conductive polypropylene)  
Herewith we declare that the supplied version of the Pneumatic Double Diaphragm Pumps  
with ordner no.  
U552.PTSS7  
U553.PHSD7  
U553.PTSS7  
complies with the following guidelines:  
2006/42/EC  
Applied standards, in particular:  
DIN EN ISO 12100: 2011  
DIN EN ISO 4414: 2011  
DIN EN 14462: 2010  
DIN EN 809: 2012  
DIN EN 12621: 2011  
DIN EN ISO 4413: 2011  
DIN EN ISO 13732-1: 2008  
Applied national technical standards and specifications, in particular:  
BGR 500 part 2 chapter 2.29 and chapter 2.36  
TRBS 2153  
Identification:  
CE Certificate of Conformity  
The CE certificate of conformity is enclosed with this product. If needed, further copies  
can be ordered through your WAGNER dealer by specifying the product name and serial  
number.  
Order number:  
2334619  
61  
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VERSION 12/2012  
ORDER NUMBER DOC 2330426  
OPERATING MANUAL  
Germany  
Switzerland  
J.WAGNER GmbH  
J.WAGNER AG  
Otto-Lilienthal-Str. 18  
Postfach 1120  
Industriestrasse 22  
Postfach 663  
D- 88677 Markdorf  
CH- 9450 Altstätten  
Telephone: +49 7544 5050  
Telefax: +49 7544 505200  
E-Mail: [email protected]  
Telephone: +41 (0)71 757 2211  
Telefax: +41 (0)71 757 2222  
E-Mail: [email protected]  
Belgium  
Denmark  
WSB Finishing Equipment  
Veilinglaan 56/58  
B- 1861 Wolvertem  
WAGNER Industrial Solution Scandinavia  
Viborgvej 100, Skærgær  
DK- 8600 Silkeborg  
Telephone: +32 (0)2 269 4675  
Telefax: +32 (0)2 269 7845  
Telephone: +45 70 200 245  
Telefax: +45 86 856 027  
E-Mail: [email protected] / HP www.wsb-wagner.eu E-Mail [email protected]  
United Kingdom  
France  
WAGNER Spraytech (UK) Ltd.  
Haslemere Way  
J.WAGNER France S.A.R.L.  
Parc de Gutenberg - Bâtiment F8  
8, Voie la Cardon  
F- 91127 Palaiseau-Cedex  
Telephone: +33 1 825 011 111  
Telefax: +33 1691 946 55  
Tramway Industrial Estate  
GB- Banbury, OXON OX16 8TY  
Telephone: +44 (0)1295 265 353  
Telefax: +44 (0)1295 269861  
E-Mail: [email protected]  
E-Mail: [email protected]  
Netherlands  
Italy  
WSB Finishing Equipment B.V.  
De Heldinnenlaan 200  
NL- 3543 MB Utrecht  
WAGNER COLORA S.r.l  
Via Fermi, 3  
I- 20875 Burago di Molgora (MB)  
Telephone: +31 (0) 30 241 4155  
Telefax: +31 (0) 30 241 1787  
Telephone: +39 039 625021  
Telefax: +39 039 6851800  
E-Mail: [email protected] / HP www.wsb-wagner.eu  
E-Mail: [email protected]  
Japan  
Austria  
WAGNER Spraytech Ltd.  
2-35, Shinden Nishimachi  
J- Daito Shi, Osaka, 574-0057  
J.WAGNER GmbH  
Otto-Lilienthal-Str. 18  
Postfach 1120  
D- 88677 Markdorf  
Telephone: +81 (0) 720 874 3561  
Telefax: +81/ (0) 720 874 3426  
E-Mail: [email protected]  
Telephone: +49 (0) 7544 5050  
Telefax: +49 (0) 7544 505200  
E-Mail: [email protected]  
Sweden  
Spain  
WAGNER Industrial Solutions Scandinavia  
Skolgatan 61  
WAGNER Spraytech Iberica S.A.  
Ctra. N- 340, Km. 1245,4  
SE- 568 31 Skillingaryd  
E- 08750 Molins de Rei (Barcelona)  
Telephone: +34 (0) 93 680 0028  
Telefax: +34 (0) 93 668 0156  
E-Mail: [email protected]  
Telephone: +46 (0) 370 798 30  
Telefax: +46 (0) 370 798 48  
E-Mail: [email protected]  
Czechoslovakia  
USA  
WAGNER s.r.o.  
Nedasovská Str. 345  
15521 Praha 5 - Zlicin  
Telephone: +42 (0) 2 579 50 412  
Telefax: +42 (0)2 579 51 052  
E-Mail: [email protected]  
WAGNER Systems Inc.  
300 Airport Road, unit 1  
Elgin, IL 60123 USA  
Telephone: +1 630 503 2400  
Telefax: +1 630 503 2377  
E-Mail: [email protected]  
62  
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Order No. 2330426  
People‘s Republic of China  
Tel.  
Fax  
+86 / (0)21 6652 / 1858  
+86 / (0)21 6630 / 8085  
Germany  
Tel.  
Fax  
E-mail  
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