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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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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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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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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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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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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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:

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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow applicable directives concerning occupational safety and accident
prevention regulations.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Danger of electric shock!
Danger to life from electric shock.
Prepare device in accordance with the applicable safety requirements with regard
to the operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Do not disconnect any plug connections during operation.
Label plug connections with the warning "Do not disconnect under voltage".
Must be repaired immediately in the event of problems.
Decommission if device poses a danger or is damaged.
Must be de-energized before work is commenced. Secure the device against being
switched back on without authorization. Inform personnel about planned work.
Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.

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4.1.2 A SAFE WORK ENVIRONMENT
Danger due to dust formation!
Severe or fatal injuries due to explosion danger or inhalation, swallowing or contact with
the skin or eyes.
The oor in the working area must be electrostatically conductive (measurements
according to EN 1081 and EN 61340-4-1).
In the spray booth, coating may only be performed with correctly designed and
locked technical ventilation.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g., mechanical
stress, corrosion).
Ensure that personal protective equipment (see chapter 4.2.1) is available and is used.
Make sure that all people within the work area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
A suitable system for suppressing re and explosion must be installed.
The powder release must be electrically interlocked with the connected technical
ventilation of the spray system.
Excess coating product (overspray) must be collected up safely.
Accumulations of powder in the spray booth are to be avoided. Set the parameters
of the oor cleaning and manually clean the spray booth as needed.
The operating company must ensure that an average concentration of powder
lacquer in the air does not exceed 50% of the lower explosion limit (LEL = max.
permitted concentration of powder to air). If no reliable LEL value is available, the
average concentration must not exceed 20 g/m³.
Ensure that maintenance and safety checks are performed regularly.
In case of defects, immediately shut down and repair the device or system before
switching it back on. Accumulations of powder are to be removed before switching
the system back on.
4.1.3 PERSONNEL QUALIFICATIONS
Danger due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.

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4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always observe the information in this manual, particularly the safety instructions
and the warning instructions.
Always follow existing regulations concerning occupational safety and accident
prevention regulations.
In electrostatics applications: Persons belonging to a risk group according to>
EMF guideline 2013/35/EU (e.g., carriers of active implants), must not enter the
high-voltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Danger due to dust formation!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
Observe the processing regulations laid down by the manufacturer of the powder
lacquer being used, when preparing or processing the powder.
Take note of the manufacturer’s notication and the relevant environmental
protection regulations when disposing of powder lacquers.
Take the specied protective measures. In particular, wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental protection, only operate the device with
technical ventilation (extraction) switched on.
4.2.2 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
Danger due to dust formation!
Do not point spray guns at people.
Do not spray device parts using electrostatic equipment.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the
"Troubleshooting" chapter.
Carry out the work steps in accordance with the chapter on pressure relief in the
operating manual of the corresponding device:
– if pressure relief is required,
– if the coating work is interrupted or stopped,
– before the device is cleaned on the outside, checked, or serviced,
– before the spray nozzle is installed or cleaned.

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4.2.3 GROUNDING THE DEVICE
Danger due to electrostatic charge!
Explosion hazard and damage to the device.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. Flames or sparks can form during discharge.
Correct grounding of the entire coating system prevents electrostatic charges:
Ensure that all devices and tanks are grounded before each coating process.
All of the system's conductive elements, such as oors, walls, ceilings, protective
grating, transport equipment, work pieces, powder tanks, automatic moving devices
or construction parts etc. in the spray area, with the exception of parts which carry
high voltage during operation, must be connected to the grounding system.
Parts of the spray booth must be grounded.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Grounding cables must be checked regularly to ensure that they are serviceable
(see EN 60204).
4.2.4 PRODUCT HOSES
Danger due to damaged product hoses!
The product hose may cause dangerous injuries.
Use only an original WAGNER powder hose.
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
– in high-traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses
are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the device.
WARNING
Bursting powder hose!
Risk of injury and damage to the device.
The powder hose may be loaded with a maximum pressure of 0.6 MPa; 6 bar; 87 psi.

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4.2.5 ELECTRICAL CONNECTION CABLES
Risk caused by improperly laid cables!
Risk of injury and damage to the device.
Properly lay connection cables and check them regularly.
Immediately replace damaged connection cables.
Ensure that no work is ever performed with a damaged connection cable.
Do not lay connection cables on routes used by product handling vehicles and not
through doors/gates.
Do not route connection cables near aisles or walkways in order to avoid tripping.
4.2.6 CLEANING AND FLUSHING
Danger due to cleaning and ushing!
Explosion hazard and damage to the device.
Before starting cleaning or any other manual work, the high voltage in the spray area
must be shut down and locked to prevent it from being switched back on.
Lock the compressed air supply and decompress the device.
Secure the device against being switched back on without authorization.
Use only electrically conducting and grounded tanks for cleaning uids.
Preference should be given to non-ignitable cleaning uids.
If ignitable cleaning uids are used, all parts carrying high voltage must be discharged
to a discharge energy of less than 0.24 mJ, once the high voltage has been switched
o, before they can be reached. Most ignitable solvents have an ignition energy of
around 0.24 mJ or 60 nC.
The cleaning agent's ash point must be at least 15 K above the ambient temperature.
Note the details provided by the powder lacquer manufacturer.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used for
getting rid of dust build-up.
Take measures for workplace safety (see chapter 4.1.2).

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4.2.7 MAINTENANCE AND REPAIR
Danger due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a specially trained person may carry out repairs
and replace parts.
Repair or replacement of devices or parts of devices are only allowed to be performed
outside the hazard area by qualied personnel.
Use only WAGNER original spare parts and accessories.
WAGNER assumes no liability for changes to the product made by the operating
company without the knowledge of WAGNER. Any adjustments to the
documentation and the market release are the responsibility of the operating
company.
Only repair and replace parts that are listed in the chapters "Accessories" and
"Spare parts" and that are assigned to the device.
Do not use any defective components.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
Observe the operating and service manual for all work.
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Danger due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.

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5 DESCRIPTION
5.1 VARIANTS
5.1.1 PERISTALTIC PUMP PP25
Model, straight Model, with elbow
P_02873
PP25S PP25C
5.1.2 PERISTALTIC PUMP PP40
Model, straight Model, with elbow
P_02874
PP40S PP40C

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5.1.3 PERISTALTIC PUMP PP25Y
Thread design Flange version
P_02875
PP25Y PP25Y-FL
5.1.4 PERISTALTIC PUMP PP40Y
Thread design
P_03084
PP40Y

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EDITION 08/2022 ORDER NUMBER DOC2368104 Peristaltic pump
5.2 TECHNICAL DATA
5.2.1 TECHNICAL DATA FOR PP25/PP40
PP25S PP25C PP40S PP40C
Input air pressure (control cabinet) 0.6-0.8 MPa; 6-8 bar; 87-116 psi
Air consumption 5 Nm/h 5 Nm/h 6 Nm/h 6 Nm/h
Control cabinet dimensions 600x600x210 mm
Maximum powder feed path 20 m; 65.62 ft
Maximum powder feed height 3.5 m; 11.50 ft
Flow rate approx. 2.1 kg/
min
approx. 1.8 kg/
min
approx. 4.5 kg/
min
4.0 kg/min
Threaded connection G1½" inside G1½" inside G2½" inside G2½" inside
Coupling connection Kamlok, 1"
5.2.2 TECHNICAL DATA FOR PP25Y/PP40Y
PP25Y PP25Y-FL PP40Y
Input air pressure (control cabinet) 0.6-0.8 MPa; 6-8 bar; 87-116 psi
Air consumption 5.5 Nm/h 7.0 Nm/h
Control cabinet dimensions 600x380x210 mm
Maximum powder feed path 20 m; 65.62 ft
Maximum powder feed height 3.5 m; 11.50 ft
Flow rate up to 1.7 kg/min
(DN14)
up to 1.7 kg/min
(DN14)
up to 2.6 kg/min
(DN20)
up to 2.6 kg/min
(DN20)
up to 4.0 kg/min
(DN20)
Threaded connection G1½" inside Flange DN40 G2½" inside
Coupling connection Kamlok, ¾"
Waste line Spiral hose, DN20
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Insucient paint application quality
Provide compressed air free from oil and water
(Quality Standard 6.5.2 according to ISO 8573.1, 2010)
6.5.2 = particle density ≤ 5 mg/m; pressure dew point ≤ +7 °C;
oil content ≤ 0.1mg/m

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5.2.3 DIMENSIONS OF PP25/PP40
PP25S PP25C
284
605
431
321
P_02848
PP40S PP40C
300
666
450
528
P_04677