ZICOM50E - Compressor Zipper - Free user manual and instructions

USER MANUAL ZICOM50E Zipper

CE-Conformal! - This product complies with the EC-directives.

READ THE MANUAL! Read the user and maintenance manual carefully and get familiar with the controls in order to use the machine correctly and to avoid injuries and machine defects.

ATTENTION! Ignoring the safety signs and warnings applied on the machine as well as ignoring the security and operating instructions can cause serious injuries and even lead to death.

Wear protective equipment!

It is forbidden to remove the protection devices and safety devices.

Attention! Motor starts automatically!

11 PREFACE (EN) Dear Customer! This manual contains information and important notes for safe commissioning and handling of the air compressors ZI-COM24E and ZI-COM50E, hereinafter referred to as “machine” in this document.

This manual is part of the machine and must not be removed. Save it for later reference and if you let other people use the machine, add this manual to the machine.

Please read and note the safety instructions! Before first use read this manual carefully. It eases the correct use of the machine and prevents misunderstanding and damages of machine. Due to constant advancements in product design, construction, illustrations and contents may deviate slightly. If you notice any errors, please inform us. We reserve the right to make technical changes! Check the goods immediately after receipt and note any complaints on the consignment note when taking over the goods from the deliverer! Transport damage must be reported separately to us within 24 hours. ZIPPER MASCHINEN GmbH cannot accept any liability for transport damage that has not been reported. Copyright © 2023 This documentation is protected by copyright. All rights reserved! In particular, the reprint, translation and extraction of photos and illustrations will be prosecuted. The place of jurisdiction is the regional court Linz or the court responsible for 4170 Haslach is valid.

Customer service contact

12 SAFETY This section contains information and important notes on the safe commissioning and handling of the machine. For your safety, read this manual carefully before commissioning. This will enable you to handle the machine safely and thus prevent misunderstandings as well as personal injury and damage to property. Pay special attention to the symbols and pictograms used on the machine as well as the safety information and danger warnings!

12.1 Intended use of the machine

The machine is designed exclusively for the following activities: For the generation of compressed air within the technical data. The machine can be used in various work fields such as refilling car tires or with pneumatic tools such as nailers, staplers, air vibrating grinders or similar.

12.1.1 Technical Restrictions

The machine is designed for the work under the following conditions: Relative humidity: max. 70 % Temperature (for operation) +10° C to +40° C Temperature (storage, transport) -25° C to +55° C

12.1.2 Prohibited applications / Dangerous misuse

• Operating the machine without adequate physical and mental fitness.

• Operating the machine without knowledge of the manual.

• Modifying the machine design.

• Operating the machine in a potentially explosive environment.

• Operating the machine outside the technical limits specified in this manual.

• Removing of the safety markings attached to the machine.

• Modifying, circumventing or disabling the safety devices of the machine.

• The machine is not designed for continuous operation or unrestricted, commercial operation and may only be used in dry rooms.

• To aim the compressed air gun at persons is prohibited. The non-intended use or the disregard of the explanations and instructions described in this manual will result in the expiration of all warranty claims and compensation claims for damages against ZIPPER MASCHINEN GmbH.

12.2 User Requirements

The machine is designed to be operated by one person. The prerequisites for operating the machine are physical and mental fitness as well as knowledge and understanding of the operating instructions. Persons who, due to their physical, sensory or mental capabilities, inexperience or lack of knowledge, are unable to operate the machine safely must not use the machine without supervision or instruction by a responsible person. Please note that locally applicable laws and regulations determine the minimum age of the operator and may restrict the use of this machine! Work on electrical components or equipment may only be carried out by a qualified electrician or under the guidance and supervision of a qualified electrician. Put on your personal protective equipment before working on the machine.

The machine is equipped with the following safety devices:

12.4 General safety instructions

To avoid malfunctions, damage and health impairments when working with the machine, the following points must be observed in addition to the general rules for safe working:

• Check the machine for completeness and function before starting. Only use the machine if the separating and other non-separating protective devices required for machining have are fitted.

• Make sure that the guards are in good working order and properly maintained.

• Select a level, vibration-free surface as the installation area. NOTE

ZIPPER MASCHINEN GmbH assumes no responsibility or warranty for any other use or use beyond this and for any resulting damage to property or injury.SAFETY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 26

ZI-COM24E | ZI-COM50E

• Ensure sufficient space around the machine.

• Ensure sufficient lighting conditions at the workplace to avoid stroboscopic effects.

• Ensure a clean working environment.

• Keep the area around the machine free of obstacles (e.g. dust, cut-off workpiece parts, etc.).

• Only use tools that are in perfect condition and free of cracks and other defects (e.g. deformations).

• Remove tool keys and other setting tools before switching on the machine.

• Check the machine's connections for strength before each use.

• Never leave the running machine unattended. Switch off the machine before leaving the working area and secure it against unintentional or unauthorized restarting.

• The machine may only be operated, maintained or repaired by persons who are familiar and who have been informed about the dangers arising from this work.

• Ensure that unauthorized persons keep a safety distance from the machine and keep children away from the machine.

• Always work with care and the necessary caution and never use excessive force.

• Do not overload the machine.

• Hide long hair under hair protection.

• Wear close fitting protective work clothing and suitable protective equipment (eye protection, face protection, ear protection S1).

• Never wear loose jewellery, loose clothing or accessories (e.g. tie, scarf).

• Do not work on the machine if you are tired, not concentrated or under the influence of medication, alcohol or drugs!

• Do not use the machine in areas where vapours of paints, solvents or flammable liquids represent a potential danger (danger of fire or explosion!).

• Shut down the machine and disconnect it from the power supply, before adjustment, changeover, cleaning, maintenance or repair work, etc. Before starting work on the machine, wait until all tools or machine parts have come to a complete standstill and secure the machine against unintentional restart.

12.5 Electrical safety

• Make sure that the machine is grounded.

• Only use suitable extension cables.

• A damaged or tangled cable increases the risk of electric shock. Handle the cable with care. Never use the cable to carry, pull or disconnect the power tool. Keep the cable away from heat, oil, sharp edges or moving parts.

• Proper plugs and outlets reduce the risk of electric shock.

• Water entry into the machine increases the risk of electric shock. Do not expose the machine to rain or moisture.

• The machine may only be used if the power supply is protected by a residual current circuit breaker.

• Before connecting the machine always make sure that the main switch is switched off.

• Use the machine only when the ON-OFF switch is in good working order.

12.6 Special safety instructions for this machine

• The machine may only be operated in suitable rooms (well ventilated, ambient temperature +5°C to 40°C). There must be no dust, acids, vapour, explosive or flammable gases in the room.

• The machine may only be operated by one person.

• Ensure that the machine is turned off before connecting it to the power supply.

• Do not place rags, containers or other materials on top of the machine. Safety instructions when working with compressed air guns

• Compressors and pipes reach high temperatures during operation. Touching them lead to burns.

• When loosening the hose coupling, hold the coupling piece of the hose with your hand. This prevents injuries caused by a rebounding hose. Safety instructions when paint spraying

• Do not use paints or solvents with a flash point of less than 55° C.

• Do not heat paints and solvents.

• If liquids harmful to health are processed, filter units (face masks) are required for protection. Please also observe the information on protective measures provided by the manufacturers of such substances.

• Observe the information and markings on the outer packaging of the processed materials in accordance with the German Ordinance on Hazardous Substances. If necessary, additional protective measures must be taken, in particular suitable clothing and masks must be worn.

• Smoking is not permitted during the spraying process or in the working area. Paint vapours are also highly flammable.

• Do not store or consume food and beverages in the work area. Paint fumes are harmful.

• The working space must be larger than 30 m

and sufficient air exchange must be ensured during spraying and drying. Do not spray against the wind. Always observe the regulations of the local authorities when spraying flammable or dangerous spray materials.

• In connection with the PVC pressure hose, do not use media such as white spirit, butyl alcohol and methylene chloride (reduced service life). Operation of pressure vessels

• Anyone who operates a pressure vessel has this to get in proper condition, operate it properly, monitor, make any necessary maintenance and repair work without delay and to meet the circumstances necessary security measures.

• A pressure vessel may not be operated if it has defects or will endanger employees or third persons.

• The pressure vessel must be checked regularly for damage, e.g. rust.

Despite intended use, certain residual risk factors remain. Due to the structure and construction of the machine, hazardous situations may occur which are identified in this manual as follows: DANGER

A safety instruction designed in this way indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Such a safety instruction indicates a potentially hazardous situation which, if not avoided, may result in serious injury or even death.

A safety instruction designed in this way indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

A safety note designed in this way indicates a potentially dangerous situation which, if not avoided, may result in property damage. Regardless of all safety regulations, your common sense and your appropriate technical aptitude/training are and remain the most important safety factor in the error-free operation of the machine. Safe working depends on you! 13 TRANSPORT Transport the machine in its packaging to the place of installation. To manoeuvre the machine in the packaging, a pallet truck or forklift truck with the appropriate lifting force can be used, for example. The specifications can be found in the chapter Technical data. For proper transport, also observe the instructions and information on the transport packaging regarding centre of gravity, lifting points, weight, means of transport to be used as well as the prescribed transport position etc. Ensure that the selected lifting equipment (crane, forklift, pallet truck, load sling, etc.) is in perfect condition. Ensure the correct body posture when lifting, carrying and setting down the load. Assembled and over short distances, the machine can also be transported by means of its wheels: Lift the machine only by the transport handle. Grasp it with both hands and lift the machine from your knees. Now the machine can be moved by its wheels.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 28

Check the delivery immediately for transport damage and missing parts. Report any damage or missing parts to your dealer or the shipping company immediately. Visible transport damage must also be noted immediately on the delivery note in accordance with the provisions of the warranty, otherwise the goods are deemed to have been properly accepted.

14.1.2 Requirements for the installation site

The selected installation site must ensure a suitable connection to the power supply. Place the machine on a level, solid surface. The space requirement by the machine including a distance of approx. 50 centimetres to walls and other objects result from the technical data (dimensions, weight) of your machine. When dimensioning the required space, take into account that an unobstructed air supply to the machine must be ensured and that the operation, maintenance and repair of the machine must be possible without restrictions at all times. The chosen installation site of the machine must comply with the local safety regulations as well as the ergonomic requirements for a workplace with sufficient lighting conditions.

The machine comes pre-assembled, it is necessary to assemble the components dismantled for transport according to the following instructions and to make the electrical connection.

• Install the wheel (2) on the wheel holder using the hexagon head screw (1), a washer (3) and a nut (4).

• Repeat the procedure with the second wheel.

• Attach the rubber foot (1) to the holder with the enclosed mounting material (see illustration on the left).

3. Attach air filter

• Install the air filter (1) on the machine (see illustration on the left).

• Remove any blank cover previously.

• Remove the transport plug from the oil filler opening.

• Screw in the oil filler cap (1) as illustrated on the left.

14.3 Electrical connection

Dangerous electrical voltage! Risk of injury due to dangerous electrical voltage!

The machine may only be connected to the power supply and the associated checks carried out by a qualified electrician or under the instruction and supervision of a qualified electrician!

• Check, whether the neutral connection (if existing) and the protective grounding function properly.

Deviation of the supply voltage and frequency! A deviation from the value of the supply voltage of ±5 % is permissible. A short-circuit fuse must be provided in the power supply system of the machine!

• Use a supply cable that fulfils the electrical requirements (e.g. H07RN, H05RN) and take the required cross-section of the supply cable from a current carrying capacity table. Pay attention to the measures for protection against mechanical damage.

• Make sure that the power supply is protected by a residual current circuit breaker.

• Connect the machine only to a properly grounded outlet.

• When using an extension cable, make sure that the dimension matches the connected load of the machine. The connection power can be found in the technical data, the correlation of cable cross- section and cable lengths can be found in the technical literature or obtain information from a specialist electrician.

• A damaged cable must be replaced immediately. 15 OPERATION Only operate the machine when it is in a perfect condition. Before each operation, a visual inspection of the machine must be carried out. Safety devices and operating elements must be checked carefully. Check screw connections for damage and tight fit.

15.1 Information on initial start-up

Waste oils are toxic and must not be released into the environment! Contact your local authorities for information on proper disposal. WARNING

ATTENTION! For transport oil has been drained. Fill up with recommended oil before first operation! Failure to do so will result in permanent engine damage and void guarantee!

• Place the machine on a level surface.

• Open the oil filler cap (1).

• Fill in recommended oil up to the central marking in the oil sight glass (2).

Close the oil filler cap (1) again. Before initial start-up of the machine, lubrication of the pistons and bearings must be ensured. Check that sufficient oil has been filled in and follow the steps below:

• Open the drain valve at the bottom of the vessel so that the air can escape and no pressure can build up in the vessel.

• Run the machine for at least 20 minutes to lubricate the piston and bearings.

• Close the drain valve of the vessel.

• After this procedure, the oil level must be checked again.

• The machine is now ready to use.

Dangerous electrical voltage! Risk of injury due to dangerous electrical voltage!

Always disconnect the machine from the power supply before performing machine settings and secure it against unintentional reconnection.

• The oil level in the compressor pump has to be checked before each use.

• The machine should be set up near the working consumer. Avoid long air lines and long supply lines (extensions).

• Make sure the intake air is dry and dust-free.

• Do not set up the machine in damp or wet areas.

• The machine must be operated on firm, level ground.

• Safety valve must be closed before the start.

• When removing the hose coupling, hold the coupling piece of the hose by hand. So the injury from rebounding hose is avoided.

15.3.1 Switch the machine on and off

15.3.2 Set the working pressure

• The working pressure can be set with the pressure regulator (1). o Clockwise rotation: The air pressure is increased.

Counterclockwise rotation: The air pressure is reduced.

• The set working pressure is indicated on the gauge (2).

15.3.3 Read the vessel pressure

• The vessel pressure is indicated on the gauge (1).

15.3.4 Establishing the compressed air connection

• Air coupling (1): To connect a consumer, insert the air pressure hose with correct adapter in the quick-coupling of the machine.

• To disconnect, pull back the sleeve of the quick-coupling and remove the hose.

Handling the machine with connected power supply may result in serious injury or death.

Alway s disconnect the machine from the power supply before cleaning, maintenance or repair work and secure it against unintentional reconnection.

Regular cleaning guarantees the long service life of your machine and is a prerequisite for its safe operation.

Incorrect cleaning products can attack the finish of the machine. Do not use any solvents, nitro thinners or other cleaning products that could damage the machine's finish. Observe the specifications and instructions of the cleaning agent manufacturer.

• After each use, remove dust and dirt particles from the machine, especially from the guards, air slots and motor housing.

• Clean the machine with a damp cloth and, if necessary, some commercial detergent or blow it out with compressed air at low pressure.

• Lubricate bare machine parts with an acid-free lubricating oil (e.g. WD40 rust inhibitor).

The machine is low-maintenance and only a few parts need to be serviced. Malfunctions or defects that could affect your safety must be repaired immediately!

• Before each operation, check the perfect condition of the safety devices.

• Regularly check the perfect and legible condition of the warning and safety labels of the machine.

• Use only proper and suitable tools.

• Use only original spare parts recommended by the manufacturer.

16.2.1 Maintenance plan

The type and degree of machine wear depends to a large extent on the operating conditions. The following intervals apply when the machine is used within the technical limits: Interval Components Action before usage

• check and refill oil if necessary after usage

• clean every 20-30 working hours

16.2.2 Clean / exchange the air filter

NOTE: A clogged and dirty air filter significantly reduces the performance of the machine!

• Loosen and remove the air filter cover (1).

• Take out the air filter.

• Clean the air filter with compressed air at low pressure.

• Reinsert the filter and reinstall the air filter cover (1).

• If too dirty, replace / exchange the air filter.

16.2.3 Drain the condensed water

To ensure a long service life of the vessel, drain off the condensed water by opening the drain valve each time after using. The condensation water from the vessel will contain residual oil. Dispose of the condensation water in an environmentally compatible manner. NOTE

Waste oils are toxic and must not be released into the environment! Contact your local authorities for information on proper disposal.

• The drain valve (1) is located at the bottom of the vessel.

• Open the drain valve (1) to drain the condensed water. NOTE: the drain valve should always be opened slowly to avoid damage to the machine and possible injury.

• Drain the condensed water into a suitable container.

• Then close the drain valve (1) again.

16.2.4 Change the oil

Waste oils are toxic and must not be released into the environment! Contact your local authorities for information on proper disposal.TROUBLESHOOTING ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 32

• Drain the oil tank by opening the drain plug (1). NOTE: as soon as the drain plug (1) is loosened, the oil runs out. For this reason, a suitable container must be positioned to collect the oil even before the drain plug is loosened.

• Afterwards, reinstall the drain plug (1).

• Then, new oil can be filled in. To do this, open the oil filler cap (2).

• Fill recommended oil up to the center mark in the oil sight glass.

• Close the oil filler cap (2) again.

• Now let the machine run at idle for 2-3 minutes (see Information on initial start-up) and then check the oil level again.

• Let the machine cool down.

• Bleed machine / depressurize machine. Store the machine in a dry, frost-proof and lockable place when not in use. Disconnect the machine from the power supply. Make sure that unauthorised persons and especially children do not have access to the machine. NOTE

Improper storage can damage and destroy important components. Only store packed or already unpacked parts under the intended ambient conditions!

Observe the national waste disposal regulations. Never dispose of the machine, machine components or operating equipment in the residual waste. If necessary, contact your local authorities for information regarding available disposal options. If you purchase a new machine or equivalent equipment from your specialist dealer, he is obliged in certain countries to dispose of your old machine properly. 17 TROUBLESHOOTING WARNING

Danger due to electrical voltage! Handling the machine with connected power supply may result in serious injury or death.

Disconnect the machine from the power supply before starting work to eliminate defects!

Many possible sources of error can be eliminated in advance if the machine is properly connected to the power supply. If you are unable to carry out the necessary repairs properly and/or do not have the required training, always consult a specialist to solve the problem. Trouble Possible cause Solution Pressure can no longer be stored

• defective valves in the cylinder head

• replace the valves Motor will not start

• check the connection to an existing electrical grid

• Overl oad protection activated

• let the motor cool down and then pull the red pressure switch (ON/OFF) After reaching the escapes cut- off pressure compressed air escapes through the relief valve below the pressure switch to reach the starting pressure

• leaking or defective check valve

• clean or replace check valve insert

• check valve is damaged • replace valve Machine on frequently

• very much condensate in the vessel

19.1.1 Restrictions techniques

(EN) With original ZIPPER spare parts you use parts that are attuned to each other shorten the installation time and elongate your products lifespan. NOTE

The installation of parts other than original spare parts leads to the loss of the guarantee! Therefore: When replacing components/parts, only use spare parts recommended by the manufacturer. Order the spare parts directly on our homepage – category SPARE PARTS or contact our customer service

Cylinder head screw M6×35 4

release pipe screw M10x1 2

67 Crank screw M6×20 1

71 Front cover screw M5×19 4

Oil seal Ø16×Ø28×7 1

85 GUARANTEE TERMS (EN) 1.) Warranty: ZIPPER machines are subject to the legal warranty, which is valid in the current version. (For electrical and mechanical components, this is equivalent to 2 years (excluding wearing parts and batteries), starting from the date of purchase by the end user/buyer. For rechargeable batteries and batteries, the legal warranty of 6 months applies, starting from the date of purchase by the end user/buyer). In case of defects during this period, which are not excluded by paragraph 3, ZIPPER will repair or replace the machine at its own discretion. 2.) Report: In order to check the legitimacy of warranty claims, the final consumer must contact his dealer. The dealer has to report in written form the occurred defect to ZIPPER. If the warranty claim is legitimate, ZIPPER will pick up the defective machine from the dealer. Returned shippings by dealers which have not been coordinated with ZIPPER, will not be accepted and refused. 3.) Regulations: a) Warranty claims will only be accepted, when a copy of the original invoice or cash voucher from the trading partner of ZIPPER is enclosed to the machine. The warranty claim expires if the accessories belonging to the machine are missing. b) The warranty does not include free checking, maintenance, inspection or service works on the machine. Defects due to incorrect usage of the final consumer or his dealer will not be accepted as warranty claims either. Some examples: usage of wrong fuel, frost damages in water tanks, leaving fuel in the tank during the winter, etc. c) Defects on wear parts are excluded, e.g. carbon brushes, collection bags, knives, cylinders, cutting blades, clutches, sealings, wheels, saw blades, splitting crosses, riving knives, riving knife extensions, hydraulic oils, oil/air/fuel filters, chains, spark plugs, sliding blocks, etc. d) Also excluded are damages on the machine caused by incorrect or inappropriate usage, if it was used for a purpose which the machine is not supposed to, ignoring the user manual, force majeure, repairs or technical manipulations by not authorized workshops or by the customer himself, usage of non-original ZIPPER spare parts or accessories. e) After inspection by our qualified personnel, resulted costs (like freight charges) and expenses for not legitimated warranty claims will be charged to the final customer or dealer. f) In case of defective machines outside the warranty period, we will only repair after advance payment or dealer’s invoice according to the cost estimate (incl. freight costs) of ZIPPER. g) Warranty claims can only be granted for customers of an authorized ZIPPER dealer who directly purchased the machine from ZIPPER. These claims are not transferable in case of multiple sales of the machine. 4.) Claims for compensation and other liabilities: The liability of company ZIPPER is limited to the value of goods in all cases. Claims for compensation because of poor performance, lacks, damages or loss of earnings due to defects during the warranty period will not be accepted. ZIPPER insists on its right to subsequent improvement of the machine. SERVICE After Guarantee and warranty expiration specialist repair shops can perform maintenance and repair jobs. But we are still at your service as well with spare parts and/or product service. Place your spare part/repair service cost inquiry by

Impressions and suggestions for improvement. - Experiences that may be useful for other users and for product design - Experiences with malfunctions that occur in specific operation modes

We would like to ask you to note down your experiences and observations and send them to us via E-Mail or by post: Meine Beobachtungen / My experiences: