WAGNER Cobra 40-10 Translation Of The Original Operating Manual Download Page 1

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B_07935

High-pressure double diaphragm pumps

Cobra 40-10; Cobra 40-25

Translation of the Original Operating Manual

II 2 G Ex h IIB T6 Gb X

For professional use.
Always observe the information in this manual, particularly the safety
instructions and the warning instructions. Store the manual in a safe place.

Edition: 05/2022

Summary of Contents for Cobra 40-10

Page 1: ...ra 40 25 Translation of the Original Operating Manual II 2 G Ex h IIB T6 Gb X For professional use Always observe the information in this manual particularly the safety instructions and the warning in...

Page 2: ......

Page 3: ...rator 14 4 1 1 Electrical Devices and Equipment 14 4 1 2 A Safe Work Environment 14 4 1 3 Personnel Qualifications 15 4 2 Safety Instructions for the Personnel 15 4 2 1 Personal Safety Equipment 15 4...

Page 4: ...ing 39 7 6 Filling with Working Product 40 8 Cleaning and Maintenance 41 8 1 Cleaning 41 8 1 1 Cleaning Personnel 41 8 1 2 Decommissioning and Cleaning 41 8 1 3 Storing for Longer Periods of Time 41 8...

Page 5: ...70 14 6 Overview of the Cobra 40 25 Components 74 14 7 Cobra 40 25 Air Motor 75 14 8 Cobra 40 25 Fluid Section 78 14 9 Cobra 40 10 Inlet Valve 82 14 10 Inlet Valve Depressor 82 14 11 Cobra 40 25 Inlet...

Page 6: ...ing 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...

Page 7: ...l Language Order no Language Order no English 2340851 Japanese 2346196 French 2340852 Czech 2401681 Spanish 2340854 Hungarian 2352542 Italian 2340853 Dutch 2367400 Russian 2345830 Portuguese 2424769 C...

Page 8: ...l as the neces sary 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 rele...

Page 9: ...ith the materials recommended by WAGNER 4 Do not deactivate safety fixtures 4 Use only WAGNER original spare parts and accessories 4 The operating personnel must be trained on the basis of this operat...

Page 10: ...d Parts Wear caused by abrasive working materials is not covered by the warranty Info Contact your local WAGNER dealer and the lacquer manufacturer if you encounter application problems Typical applic...

Page 11: ...tion X 3 2 IDENTIFICATION X The maximum surface temperature corresponds to the permissible product temperature This and the permissible ambient temperature can be found in Chapter Data 8 22 Safe Handl...

Page 12: ...luid Filling and emptying Ignitable gas mixtures can form in the fluid section or product hoses if the pump must be emptied for maintenance and or repair purposes 4 Empty and fill the device slowly an...

Page 13: ...t F rdermenge DH Delivery DS D bit CD Max Luftdruck Air pressure Pression d air Max Temp Material Fluid Baujahr Serie Nr Year of manufacture Serial No Vor Gebrauch Betriebsanleitung beachten Check man...

Page 14: ...4 Decommission if device poses a danger or is damaged 4 Must be de energized before work is commenced 4 Secure the device against being switched back on without authorization 4 Inform personnel about...

Page 15: ...Personnel Qualifications Danger due to incorrect use of device Risk of death due to untrained personnel 4 Ensure that the operating personnel has been instructed by the operator in accordance with th...

Page 16: ...ician at least every 12 months for their work safe condition in accordance with DGUV regulation 100 500 Chapter 2 29 and Chapter 2 36 4 For shut down devices the examination can be suspended until the...

Page 17: ...ure from the outside in any other way 4 Ensure that the hoses are never kinked Observe maximum bending radii 4 Ensure that no work is ever performed with a damaged hose 4 Make sure that the hoses are...

Page 18: ...lvent 4 2 6 Touching Hot Surfaces Danger due to hot surfaces because of hot coating products Risk of burn injuries 4 Only touch hot surfaces if you are wearing protective gloves 4 When operating the d...

Page 19: ...ve 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 4 Protective...

Page 20: ...oduct output 5 2 FUNCTIONING The double diaphragm pump is driven with compressed air This compressed air moves the air piston in the air motor 4 and consequently the piston rod in the pressure stage 9...

Page 21: ...trol housing is equipped with noise insulation Never operate the device without noise insulation 5 4 EXTENT OF DELIVERY Stk Order no Designation 1 2329519 Diaphragm pump Cobra 40 10 consisting of Flui...

Page 22: ...26 Maximum possible strokes in operation DH min 200 Minimum maximum air inlet pressure MPa bar psi 0 25 0 6 2 5 6 36 3 87 Compressed air quality free from oil and water Quality standard 7 5 4 accordin...

Page 23: ...ssembly and operation C F 10 60 50 140 Ambient temperature Storage C F 20 60 4 140 Relative humidity 10 95 without conden sation Allowable inclination for operation 10 Hydraulic oil filling amount app...

Page 24: ...H I L G A C Cobra 40 25 K M B D E F H I K L M G A C B_07937 Cobra 40 10 Pos Cobra 40 10 mm inch Cobra 40 25 mm inch A 505 19 88 605 23 82 B 313 12 32 379 14 92 C 322 12 68 373 14 69 D 134 5 28 E 55 2...

Page 25: ...0 23 20 30 40 50 60 0 21 0 25 0 30 0 011 0 28 10 20 30 40 50 60 0 30 0 35 0 43 0 013 0 33 10 20 30 40 50 60 80 0 45 0 53 0 66 0 015 0 38 10 20 30 40 50 60 80 0 58 0 67 0 81 0 017 0 43 20 30 40 50 60...

Page 26: ...25 5 Description 26 Order number 2340851 Edition 05 2022 5 5 5 Performance Diagrams Example 8 bar 6 bar 4 bar 8 b a r 6 bar 4 bar B_00301 1 2 3 4 1 Product pressure in bar MPa psi 3 Air consumption in...

Page 27: ...n nl min scfm B Characteristic curve for air pressure 4 5 bar 0 45 MPa 65 psi 4 Flow rate of water in l min gpm C Characteristic curve for air pressure 3 bar 0 3 MPa 44 psi Cobra 40 25 B_02947 C nl mi...

Page 28: ...r 2328614 B_04301 2 3 1 Pos Positions of the ball valve 1 Open working position 2 Closed The air motor may still be under pressure 3 Vent Operating pressure in the air motor is vented control pressure...

Page 29: ...gm pumps Cobra 40 10 Cobra 40 25 5 Description Order number 2340851 Edition 05 2022 29 B_07642 2 3 1 6 4 5 7 53 MPa 530 bar 7687 psi 1 Fluid section connection 5 Open 2 Product output 6 Pressure relie...

Page 30: ...C and 60 C 4 F and 140 F The relative air humidity at the storage location must be between 10 and 95 without condensation 6 3 INSTALLATION CONDITIONS The air temperature at the installation site must...

Page 31: ...recommended The oil level must be monitored monthly Oil leaks must be expected at the oil valve screw item 67 in item 46 and at the pressure relief valve item 42 Cobra 40 10 or item 28 Cobra 40 25 see...

Page 32: ...g to the operating manual 6 5 1 Ventilation of the Spray Booth Operate the device in a spray booth approved for the respective working materials or Operate the device on an appropriate spraying wall w...

Page 33: ...the device and the spray gun are suitable for the pressure generated in the device 4 Ensure that the following information can be seen on the high pressure hose 4 Manufacturer 4 Permissible operating...

Page 34: ...6 mm AWG6 2 Work piece 3 Pump 4 mm AWG12 4 Product tank 6 mm AWG10 5 Spraying stand Alternative Spray booth 16 mm AWG6 6 Floor static dissipative Safe operation of the pump is only guaranteed with a g...

Page 35: ...ning NOTICE Impurities in the spraying system Spray gun blockage products harden in the spraying system 4 Flush the spray gun and paint supply with a suitable flushing agent before commissioning Emerg...

Page 36: ...r until maximum pressure is reached Maintain the pressure for 3 minutes and check all connection points for leaks 2 Carry out pressure relief in accordance with Chapter Pressure Relief Work Interrupti...

Page 37: ...tial risks associated with improper behavior as well as the necessary protective devices and measures Before work commences the operating personnel must receive appropriate system training 7 2 EMERGEN...

Page 38: ...Depending on the function the pump may continue running at 1 6 DH min after the spray gun is closed 7 4 PRESSURE RELIEF WORK INTERRUPTION The pressure must always be relieved after the spraying tasks...

Page 39: ...nts used must be compatible with the working material WARNING Incompatibility of cleaning flushing agent and working medium Risk of explosion and danger of poisoning by toxic gases 4 Examine the compa...

Page 40: ...alve depressors V B_01219 V Flushing via spray gun 1 In case of AirCoat systems carry out the basic flushing without atomizing air 2 Point the spray gun 3 without nozzle into the tank 5 and pull the t...

Page 41: ...ressure Relief Work Interruption 8 38 2 Carry out basic flushing in accordance with Chapter Basic Flushing 8 39 3 Empty system in a controlled manner according to Chapter Emptying Pump 8 44 4 Service...

Page 42: ...that are listed in the spare parts chapter and that are assigned to the device 4 Before all work on the device and in the event of work interruptions 4 Relieve the pressure from the spray gun product...

Page 43: ...r than every 12 months to ensure that they are in safe working order 4 For shut down devices the examination can be suspended until the next start up 8 2 4 Condensate Drain from the AirCoat Filter Reg...

Page 44: ...ife from flying parts Ignition of potentially explosive surrounding atmosphere 4 Empty and fill the device slowly and in a controlled manner 4 Avoid potentially explosive atmosphere in the surrounding...

Page 45: ...e 3 Emptying via the spray gun 1 Point the spray gun 3 without nozzle into the tank 5 and pull the trigger 2 Slowly open the ball valve 2 Be ready for the switch from working product to air 3 As soon...

Page 46: ...ng product starts coming from the return tube 4 9 Close the relief valve 3 10 Point the spray gun without nozzle into the tank 5 and open it 11 Slowly open the ball valve 2 Be prepared for the switch...

Page 47: ...h the pump and inline filter in accordance with Chapter Basic Flushing 8 39 Flush using the spray gun so that the flushing agent flows through the inline filter Maximize the flow remove the nozzle ope...

Page 48: ...sh the pump and HP filter in accordance with Chapter Basic Flushing 8 39 and while doing so 4 At the preferred filter installation position Flush via the return valve 1 This produces a large flow As a...

Page 49: ...and shake well 4 Clean the distribution housing 7 using a brush 10 If necessary replace the O ring 5 and or filter cartridge 11 Order no see Chapter High pressure Filter 530 Bar 8 85 11 Assemble all...

Page 50: ...upside down on a suitable underlay and position it horizontally B_04243 A 5 X Observe the fill level marking X on the oil tank Oil level A in the oil tank has to be within the specified markings X If...

Page 51: ...Using hydraulic oil Using the wrong hydraulic oil can cause a malfunction 4 Use only original hydraulic oil Wagner order no 322912 250 ml or 15 cu inch 8 2 11 1 Draining Oil B_07986 1 4 3 2 1 Decommis...

Page 52: ...t horizontally 2 Unscrew and remove threaded plug 5 3 Unscrew 2 locking screws 4 and replace with 2 threaded fittings 6 from the oil filling set 4 Connect hoses with Y pieces 7 5 Fill syringe 8 with h...

Page 53: ...ide down on a suitable underlay and positioned horizontally Remove the threaded plug 5 2 Slowly start up the pump vent until no more air bubbles rise from the oil suction tube 3 Oil level A in the oil...

Page 54: ...Please refer to the gun manual Irregular pump opera tion spray jet collapses pulsation Viscosity is too high Thin product Spraying pressure is too low Increase incoming air pressure Use a smaller nozz...

Page 55: ...manual High pressure double diaphragm pumps Cobra 40 10 Cobra 40 25 9 Trouble Shooting and Solution Order number 2340851 Edition 05 2022 55 If the problem is not listed above consult your WAGNER Servi...

Page 56: ...efore all work on the device and in the event of work interruptions 4 Relieve the pressure from the spray gun product hoses and all devices 4 Secure the spray gun against actuation 4 Switch off the en...

Page 57: ...nts grease or sweat from the hands salt water Perform cleaning and mounting tasks wearing gloves 10 5 ASSEMBLY OF THE DEVICE In Chapter Spare Parts 8 65 the order numbers for device spare parts can be...

Page 58: ...the individual parts of the frame mobile base 100 k 2 Check conductivity between the piston and the grounding connection 100 k These tests are relevant Ohmmeter Measurement voltage 500 1000 VDC 4 Leak...

Page 59: ...CE When the devices must be scrapped please differentiate the disposal of the waste materials The following materials have been used Stainless steel Aluminum Elastomers Plastics Carbide 12 2 CONSUMABL...

Page 60: ...7 29 30 31 32 22 16 62 12 59 60 61 14 6 9 10 19 8 18 55 56 57 33 34 58 Regarding item 7 Fitting 7 can be screwed in instead of the relief valve In this case the required ball valve must be provided by...

Page 61: ...Cobra 16 2328611 AirCoat regulator set 17 2324110 DN16 Suction Hose 18 2330774 Fitting DF MM G1 4 1 4NPSM 530bar SSt 19 2332620 Fitting RF FM G3 8 3 8NPSM 530bar SSt 20 322052 Complete Frame 21 23321...

Page 62: ...Pressure relief Relex see supplement order no 2409685 60 2401807 Fitting RF FM M36 G1 1 4 PN20 SSt 61 2401849 20 liter hopper set for Cobra 62 2356467 Ball valve set wearing parts 13 2 COBRA 40 25 ACC...

Page 63: ...ounding cable 3 m 9 8 ft 3 2382997 AirCoat filter pressure regulator 4 341434 Double open end wrench 6 2329026 Inline filter HL DN6 PN270 G1 4 SSt 7 2325343 Fitting DF MM R1 4 M12 PN270 SSt 8 2341068...

Page 64: ...F MM G3 8 M24 PN530 SSt 56 2335334 HP filter DN12 PN530 CS complete 57 2330775 Fitting DF MM G3 8 G3 8 530bar SSt 58 2330780 Fitting DF MM G1 2 G3 8 530bar SSt 59 2333058 Fitting SF FM G3 8 G1 2 530ba...

Page 65: ...marking in the following spare parts lists Wearing parts Wearing parts are not included in the warranty included in service set not part of the standard equipment but available as a special accessory...

Page 66: ...a 40 10 fluid section preassembled 3 1 322436 Air motor casing 4 1 322437 Pressure stage casing 5 1 322235 Hood 4 with air outlet 6 3 9907224 Hexagon socket head cap screw 7 4 9920106 Washer 8 1 99001...

Page 67: ...12 13 14 15 16 52 17 18 19 20 21 34 56 56 57 27 33 35 36 37 38 39 40 41 22 25 43 42 44 47 48 45 44 49 51 50 46 26 26 55 28 29 27 10 15 Nm 7 11 lbft 20 25 Nm 15 18 lbft 2 3 Nm 1 5 2 2 lbft 50 25Nm 24...

Page 68: ...tting L 26 2 367307 Sealing plug 4 6 27 2 9974085 O ring 28 1 367324 Filter holder 29 1 367314 Control air filter 30 1 322910 Cobra outlet seal set consisting of 2 seals 31 2 9974095 O ring 32 1 36828...

Page 69: ...th collar hexagon socket 52 1 9974217 Rod seal 53 1 9970154 Sealing ring 54 1 322439 Air motor noise insulation 55 1 9990861 Ribbed plug 56 2 368313 Damper ISO1 and ISO2 57 6 9971123 O ring 58 1 99925...

Page 70: ...16 91 19 69 20 21 22 23 92 24 25 67 26 102 27 4 89 90 78 110 110 13 112 105 78 70 Nm 52 lbft 90 Nm 66 lbft 30 Nm 22 lbft 50 Nm 37 lbft 2 Nm 1 5 lbft 103 20 Nm 15 lbft 20 Nm 14 8 lbft 40 Nm 29 5 lbft...

Page 71: ...G3 8 530 bar SSt 20 1 322913 Complete diaphragm set with insert comprising 2 diaphragms 21 2 9904306 Screw plug 22 2 9970127 Sealing ring 23 1 2338520 Pressure stage D19 53 24 3 9907041 Hexagon screw...

Page 72: ...ealing ring 89 2 9971486 O ring solvent resistant 90 2 341316 Scraper 91 1 9974112 Sealing ring for G3 8 thread 92 3 9920106 Washer 93 2 341325 Valve guide 94 2 341328 Clasp 95 2 9971470 O ring 96 2 3...

Page 73: ...Order number 2340851 Edition 05 2022 73 51 53 54 55 53 57 59 60 61 62 70 63 108 7 7 B_04252 29 59 30 31 32 33 34 35 111 111 40 Nm 29 5 lbft Note The piston rod 25 may only be mounted with the screwed...

Page 74: ...0106 Washer 4 1 322235 Hood 4 with air outlet 5 3 2308693 Hexagon socket head cap screw 6 1 9900107 Hexagon screw without shaft 7 1 2332077 Warning label 8 1 2332082 Fluid warning label 9 2 9920104 Wa...

Page 75: ...15 16 52 17 18 19 20 21 34 56 56 57 27 33 35 36 37 38 39 40 41 26 26 55 28 29 27 10 15 Nm 7 11 lbft 20 25 Nm 15 18 lbft 2 3 Nm 1 5 2 2 lbft 67 24 63 25Nm 63 B_06852 42 44 43 64 65 25 22 62 60 49 61 4...

Page 76: ...w with collar hexagon socket 26 2 9990506 Cone plug GPN 600 27 2 9974085 O ring 28 1 367324 Filter holder 29 1 367314 Control air filter 30 1 322910 Cobra outlet seal set consisting of 2 seals 31 2 99...

Page 77: ...1 and ISO2 57 6 9971123 O ring 58 1 9992590 Loctite 222 50 ml 50 cc 60 1 2311012 Distribution piece midi to size 4 61 1 9971137 O ring 62 1 9974166 O ring 63 3 9906020 Hexagon socket head cap screw M6...

Page 78: ...27 102 26 66 67 40 91 19 69 20 21 22 23 24 92 25 67 26 102 27 4 71 13 100 Nm 74 lbft 8 x 120 Nm 89 lbft 2 x 50 Nm 37 lbft 2 Nm 1 5 lbft 105 20 Nm 15 lbft 20 Nm 14 8 lbft 40 Nm 29 5 lbft 110 110 110 11...

Page 79: ...M G3 8 G3 8 530bar SSt 19 1 2330780 Fitting DF MM G1 2 G3 8 530bar SSt 20 1 2308754 Complete Cobra 40 25 diaphragm kit set with insert comprising 2 diaphragms 21 2 9904306 Screw plug 22 2 9970127 Seal...

Page 80: ...ve screw 68 1 9971162 O ring 69 2 2306179 Insert 70 1 9974217 Rod seal 71 2 9971486 O ring solvent resistant 72 2 341316 Scraper 73 1 9971395 O ring 10x1 25 80 1 2339251 Plug 81 1 9904311 Locking scre...

Page 81: ...uded in service set The internal thread at the product output of the fluid section item 14 will be converted as of 2014 from G1 2 to G3 8 please use the corresponding fitting and sealing ring see chap...

Page 82: ...ith fast cleaner Loctite type 7063 Pos K Stk Order no Designation 1 1 322914 Complete Cobra 40 10 inlet valve set 2 2 9912100 Hexagon nut with clamp 3 2 344334 Spring guide 4 2 190304 Pressure spring...

Page 83: ...rew plug wearing parts 14 11 COBRA 40 25 INLET VALVE B_02942 2 2 3 4 7 6 1 5 9 11 8 3 10 0 0 1 Regarding items 8 and 10 Adhesive surface Pretreated with fast cleaner Loctite type 7063 Pos K Stk Order...

Page 84: ...B_01231 Regarding position 7 Adhesive surface Pretreated with fast cleaner Loctite type 7063 Pos K Stk Order no Designation 1 1 169248 Relief valve complete 2 1 9920602 Adjusting washer 3 1 169346 Pre...

Page 85: ...Order number 2340851 Edition 05 2022 85 14 13 HIGH PRESSURE FILTER 530 BAR 30 Nm 22 lbft 140 Nm 103 lbft 12 21 11 10 1 4 7 13 20 33 2 3 5 B_03934 23 34 36 35 36 34 34 20 34 A B C D 53 MPa 530 bar 7687...

Page 86: ...21 Filter sieve 200 mesh per inch fine 14068 Filter sieve 100 mesh per inch medium mesh width 0 16 mm 3514069 Filter sieve 50 mesh per inch rough 291564 Filter sieve 20 mesh per inch rough 12 1 351405...

Page 87: ...g 90 pre assembled 6 1 9992609 Anti seize paste tube 7 1 128389 Gasket wearing parts not part of the standard equipment but available as a special accessory 14 15 STRAIGHT INLINE FILTER 270 BAR B_0407...

Page 88: ...provides contact point via container coating Pos K Stk Order no Designation AirCoat regu lator AirCoat filter regulator 1 1 2328611 AirCoat regulator set 2 1 2382997 AirCoat filter regulator set 3 1...

Page 89: ...14 17 COMPLETE COBRA FRAME B_06841 1 2 3 4 6 7 8 5 Pos K Stk Order no Designation 40 10 40 25 1 1 322052 2308732 Frame Cobra 2 1 Frame pressed 3 1 Frame pipe 4 2 9990861 Plug 5 4 9999209 Saddle feet f...

Page 90: ...Edition 05 2022 14 18 HORIZONTAL COBRA MOBILE BASE B_05001 4 3 1 2 5 6 8 7 14 12 11 9 15 10 16 5 A A 13 17 18 Axle setting Cobra mobile base Pos K Stk Order no Designation 1 1 2341375 Cobra mobile ba...

Page 91: ...ter pin 9 1 Wheel axle 4 6 complete 10 2 367943 Connecting part 4 6 11 2 Tube plug ribbed 12 4 9998685 Saddle feet for round tubes 13 2 Plug 14 1 Frame pipe long 15 2 3061695 Hexagon screw without sha...

Page 92: ...base complete 2 1 Frame left 4 6 welded 3 1 Frame right 4 6 welded 4 4 9907140 Hexagon screw DIN931 M6x75 5 6 9910204 Self locking hexagon nut M6 6 2 2304440 Wheel D250 7 4 340372 Washer 8 4 9995302 C...

Page 93: ...14 20 5 LITER TANK B_04258 2 6 4 5 3 7 1 Pos K Stk Order no Designation 1 1 2344505 Hopper set Ex 5 L 1 3 gal 2 2 9902313 Cylinder self tapping screw 3 1 3756 Filter disk mesh 0 4 mm 0 02 inch 3a 1 3...

Page 94: ...844 Union nut with bayonet 2 1 2321426 Low pressure mini ball valve G1 2 3 1 2341277 2 Liter Tank 4 1 2341532 Cover 5 2 2321676 Sieve insert SPA easy line 6 1 2320888 Cone connector preassembled 7 1 9...

Page 95: ...ISO 12100 2010 EN 14462 2015 EN 809 1998 A1 2009 AC 2010 EN 12621 2006 A1 2010 EN ISO 4413 2010 EN 1127 1 2019 EN ISO 4414 2010 EN ISO 80079 36 2016 EN ISO 13732 1 2008 EN ISO 80079 37 2016 Applied n...

Page 96: ...Operating manual High pressure double diaphragm pumps Cobra 40 10 Cobra 40 25 15 Declaration of Conformity 96 Order number 2340851 Edition 05 2022...

Page 97: ...Operating manual High pressure double diaphragm pumps Cobra 40 10 Cobra 40 25 15 Declaration of Conformity Order number 2340851 Edition 05 2022 97...

Page 98: ...Operating manual High pressure double diaphragm pumps Cobra 40 10 Cobra 40 25 15 Declaration of Conformity 98 Order number 2340851 Edition 05 2022...

Page 99: ......

Page 100: ...lephone 49 0 7544 5050 Fax 49 0 7544 505200 E mail ts liquid wagner group com Switzerland Wagner International AG Industriestrasse 22 CH 9450 Altst tten Telephone 41 0 71 757 2211 Fax 41 0 71 757 2222...

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WAGNER Cobra 40-10, Translation Of The Original Operating Manual

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Summary of Contents for Cobra 40-10

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