WAGNER PP25S Operational manual

P_02893
PP25S
PP25C
PP40S
PP40C
PP25Y
PP40Y
Peristaltic Pump System
Edition 08/2022
II 3 D Ex h IIIB T85°C Dc

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EDITION 08/2022 ORDER NUMBER DOC2368104 Peristaltic pump
Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 USING IN ACCORDANCE WITH THE INSTRUCTIONS 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 For Use in Potentially Explosive Areas 9
2.4 Processible Working Materials 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Permissible device combinations 10
3.3 Type Plate 10
4 BASIC SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Devices and Equipment 11
4.1.2 A Safe Work Environment 12
4.1.3 Personnel Qualications 12
4.2 Safety Instructions for the Personnel 13
4.2.1 Personal Safety Equipment 13
4.2.2 Safe Handling of WAGNER Powder Spray Devices 13
4.2.3 Grounding the Device 14
4.2.4 Product Hoses 14
4.2.5 Electrical Connection Cables 15
4.2.6 Cleaning and Flushing 15
4.2.7 Maintenance and Repair 16
4.2.8 Protective and Monitoring Equipment 16
5 DESCRIPTION 17
5.1 Variants 17
5.1.1 Peristaltic pump PP25 17
5.1.2 Peristaltic pump PP40 17
5.1.3 Peristaltic pump PP25Y 18
5.1.4 Peristaltic pump PP40Y 18
5.2 Technical Data 19
5.2.1 Technical Data for PP25/PP40 19
5.2.2 Technical Data for PP25Y/PP40Y 19
5.2.3 Dimensions of PP25/PP40 20
5.2.4 Dimensions of PP25Y 21
5.2.5 Dimensions of PP40Y 21
5.3 Extent of Delivery 22
5.4 Functional Description 22
5.4.1 Function Cycle of PP25/PP40 (4 Cycles) 23
5.4.2 Function Cycle of PP25/PP40 (5 Cycles) 25

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EDITION 08/2022 ORDER NUMBER DOC2368104 Peristaltic pump
5.4.3 Function Cycle of PP25Y/PP40Y, Circulation Mode (4 Cycles) 27
5.4.4 Function Cycle of PP25Y/PP40Y, Circulation Mode (5 Cycles) 29
5.4.5 Function Cycle of PP25Y/PP40Y, Spray-to-Waste Mode (4 Cycles) 31
5.4.6 Function Cycle of PP25Y/PP40Y, Spray-to-Waste Mode (5 Cycles) 33
6 ASSEMBLY AND COMMISSIONING 35
6.1 Training of Assembly/Commissioning Personnel 35
6.2 Storage Conditions 35
6.3 Installation Conditions 35
6.4 Start Up 35
6.4.1 Preparation 35
6.4.2 Recommended Settings for Compressed Air 36
6.5 Connection Diagram 36
7 OPERATION 37
7.1 Training the Operating Personnel 37
7.2 Tasks 37
8 CLEANING AND MAINTENANCE 38
8.1 Cleaning 38
8.1.1 Cleaning Personnel 38
8.1.2 Cleaning Procedures 38
8.1.3 Cleaning the Peristaltic Pump 38
8.2 Maintenance 39
8.2.1 Maintenance Personnel 39
8.2.2 Maintenance Instructions 39
8.2.3 Safety Checks and Maintenance Intervals 39
8.2.4 Maintenance Procedures 40
8.2.5 Processing the Hose Ends on the Spiral Hose 41
8.2.6 Note on the use of the couplings 43
8.2.7 Replacing the Hose Sleeve 44
8.2.8 Replacing the DN65 Hose Sleeve 45
9 TROUBLESHOOTING AND RECTIFICATION 47
10 DISASSEMBLY AND DISPOSAL 48
10.1 Disassembly 48
10.2 Disposal 48
11 ACCESSORIES 49
11.1 Accessories for PP25/PP40 49
11.1.1 Flange Set for PP25 49
11.1.2 Cyclone Discharge Adapter 49
11.1.3 Powder hose 49
11.2 Accessories for Y Peristaltic Pump 50
11.2.1 Powder Hose Set for Recovery System DN14 50
11.2.2 Powder Hose Set for Recovery System DN20 50
11.2.3 Powder Hose Set for Recovery System DN20 1" 50
11.2.4 Powder Hose Set for Recovery System IPS DN14 51
12 SPARE PARTS 53
12.1 How to Order Spare Parts 53
12.2 Peristaltic Pump PP25S, Straight (Until 11/2020) 54
12.3 Peristaltic Pump PP25S, Straight (Starting 12/2020) 56
12.4 Peristaltic Pump PP25S, with Elbow (Until 11/2020) 58

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EDITION 08/2022 ORDER NUMBER DOC2368104 Peristaltic pump
12.5 Peristaltic Pump PP25S, with Elbow (Starting 12/2020) 60
12.6 Peristaltic Pump PP40S, Straight (Until 11/2020) 62
12.7 Peristaltic Pump PP40S, Straight (Starting 12/2020) 64
12.8 Peristaltic Pump PP40C, with Elbow (Until 11/2020) 66
12.9 Peristaltic Pump PP40C, with Elbow (Starting 12/2020) 68
12.10 Peristaltic Pump PP25Y, Flange Connection (Until 11/2020) 70
12.11 Peristaltic Pump PP25Y, Flange Connection (Starting 12/2020) 72
12.12 Peristaltic Pump PP25Y, Threaded Connection (Until 11/2020) 74
12.13 Peristaltic Pump PP25Y, Threaded Connection (Starting 12/2020) 76
12.14 Peristaltic Pump PP40Y, Threaded Connection (Until 11/2020) 78
12.15 Peristaltic Pump PP40Y, Threaded Connection (Starting 12/2020) 80
12.16 Powder Hose Set DN14 82
12.17 Powder Hose Set DN20 82
12.18 Powder Hose Set DN20 1", 20 m 83
12.19 Powder Hose Set DN20 1", 25 m 83
12.20 Control Cabinets 84
12.21 Valve terminal 84
13 EU DECLARATION OF CONFORMITY 85

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EDITION 08/2022 ORDER NUMBER DOC2368104 Peristaltic pump
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 the operating and
service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in
this operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual highlight particular dangers to users and to the
device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
DANGER Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential danger.
Non-observance may result in death or serious injury.
CAUTION Potentially dangerous situation.
Non-observance may result in minor injury.
NOTICE Potentially dangerous situation.
Non-observance may result in damage to property.
Note: Provides information about particular characteristics and
how to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2368103
Translation of the original operating manual
Language Order no. Language Order no.
English 2368104 Dutch 2395079
French 2368106 Czech 2397212
Italian 2368107 Romanian 2397433
Spanish 2368108 Bulgarian 2404291
Russian 2391996 Hungarian 2411501
Danish 2393499 Polish 2406128
Swedish 2423300 Croatian 2431194
Japanese 2435049
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number
Spare part
Marking in the spare parts lists
Position
Number of pieces
Recovery system
-- Item not available as spare part
/ Item does not exist

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EDITION 08/2022 ORDER NUMBER DOC2368104 Peristaltic pump
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with compressed air
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/her,
the potential risks associated with improper behavior as well as
the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person in the
context of TRBS 1203
(2010/Revision 2012)
A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the area of electrostatic coating and is familiar
with the relevant and generally accepted rules of technology
so that he/she can inspect and assess the status of devices and
coating systems based on workplace safety.

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EDITION 08/2022 ORDER NUMBER DOC2368104 Peristaltic pump
2 USING IN ACCORDANCE WITH THE INSTRUCTIONS
2.1 DEVICE TYPE
Peristaltic pump system for feeding powder lacquers.
2.2 TYPE OF USE
The peristaltic pumps serve to feed the powder, recovered from the spray booth, to the
powder tank (e.g., powder feed center) in a way that creates very little dust.
WARNING
Dust formation!
Danger of poisoning.
Danger due to escaping dust, contamination of the device and device components.
Only operate the device in conjunction with exhaust air equipment, for example a
suction device on the powder center.
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for use in potentially explosive areas (zone 22) in accordance with
Directive 2014/34/EU.
2.4 PROCESSIBLE WORKING MATERIALS
In principle all powder lacquers can be fed with the peristaltic pump, for example epoxy,
polyester, mixed powders EP/PES/PUR.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
liquid coating products, e.g., solvents or water-based lacquers are not processed;
no food, medicine or cosmetics are processed.

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EDITION 08/2022 ORDER NUMBER DOC2368104 Peristaltic pump
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
Device type: Single peristaltic pump
Manufacturer: J. Wagner GmbH
88677 Markdorf
Germany
II 3 D Ex h IIIB T85°C Dc
CE: European Communities
Ex: Symbol for explosion protection
II: Device class II
3: Category 3 (zone 22)
D: Ex-atmosphere dust
Ex h: Ignition protection for non-electrical devices
IIIB: Explosion group
T85°C: Temperature class (< 85 °C)
Dc: Device protection level
3.2 PERMISSIBLE DEVICE COMBINATIONS
Peristaltic pump type Control cabinet order no. Remarks
1x PP25 3145536 Pneumatic system and PLC
1x PP40 2341584 Only the pneumatic system if control is
provided from the powder center
2x PP25 3145536 Pneumatic system and PLC
2x PP40 2311774 Only the pneumatic system if control is
provided from the powder center
1x PP25Y 2364179 Pneumatic system if control is provided by the
powder center
1x PP40Y
2x PP25Y 2364187 Pneumatic system if control is provided by the
powder center
2x PP40Y
3.3 TYPE PLATE
P_02932
II 3 D Ex h IIIB T85°C Dc
Typ / Type:
Serie Nr.:
Serial no.:
Baujahr:
Year of manufacture:
Temperatur Umgebung:
Ambient temperature: 0 – 40 °C
9450 Altstätten Made in Switzerland
Anschluss pneumatisch:
Pneumatic connection: