WAGNER Cobra 40-10 Montageanleitung

B_04233

B_04234

Cobra 40-10

Cobra 40-25

High-pressure

Double Diaphragm Pumps

Version 01/2018

VERSION 01/2018 ORDER NUMBER DOC 2340851 Cobra 40-10 / 40-25

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 7

2 CORRECT USE 8

2.1 Device types 8

2.2 Type of Use 8

2.3 For Use in Potentially Explosive Areas 8

2.4 Processible Working Materials 9

2.5 Misuse 9

3 IDENTIFICATION 10

3.1 Explosion protection identication 10

3.2 Identication "X" 10

3.3 Type plates 11

4 BASIC SAFETY INSTRUCTIONS 12

4.1 Safety instructions for the operator 12

4.1.1 Electrical Devices and Equipment 12

4.1.2 A Safe Work Environment 12

4.1.3 Personnel Qualications 13

4.2 Safety Instructions for Sta 13

4.2.1 Personal Safety Equipment 13

4.2.2 Safe handling of WAGNER spray devices 14

4.2.3 Ground the Unit 14

4.2.4 Product hose 15

4.2.5 Cleaning and Flushing 16

4.2.6 Touching hot surfaces 16

4.2.7 Maintenance and Repair 17

4.2.8 Protective and monitoring equipment 17

5 DESCRIPTION 18

5.1 Components 18

5.2 Mode of operation 18

5.2.1 Air motor 18

5.2.2 Fluid section 18

5.3 Protective and monitoring equipment 19

5.4 Included items 19

5.5 Data 19

5.5.1 Materials of paint wetted parts 19

5.5.2 Technical data 20

5.5.3 Dimensions and connections 21

5.5.4 Volume ow 22

5.5.5 Performance diagrams 23

5.6 Cobra Pressure Regulator Unit 24

5.6.1 High-pressure Filter (Option) 24

6 ASSEMBLY AND COMMISSIONING 25

VERSION 01/2018 ORDER NUMBER DOC 2340851 Cobra 40-10 / 40-25

6.1 Training of Assembly/Commissioning Sta 25

6.2 Storage conditions 25

6.3 Installation conditions 25

6.4 Transportation 25

6.5 Assembly and installation 26

6.5.1 Ventilation of the spray booth 27

6.5.2 Air supply lines 27

6.5.3 Product supply lines 27

6.6 Grounding 27

6.7 Commissioning 29

7 OPERATION 30

7.1 Training the operating sta 30

7.2 EMERGENCY STOP 30

7.3 Work 31

7.4 Pressure Relief/Work Interruption 31

7.5 Basic cleaning 32

7.5.1 Filling with working material 32

8 CLEANING AND MAINTENANCE 33

8.1 Cleaning 33

8.1.1 Cleaning sta 33

8.1.2 Decommissioning and Cleaning 33

8.1.3 Long-term storage 33

8.2 Maintenance 34

8.2.1 Maintenance sta 34

8.2.2 Maintenance Instructions 34

8.2.3 Safety checks and maintenance intervals 35

8.2.4 Emptying pump 36

8.2.5 Filling the empty pump 37

8.2.6 Cleaning and Replacing the Filter 38

8.2.7 Maintenance Hydraulic Stage 40

8.2.8 Checking the Oil Level 40

8.2.9 Oil change 41

9 TROUBLESHOOTING AND RECTIFICATION 44

10 REPAIR WORK 45

10.1 Repair Sta 45

10.2 Repair Notes 45

10.3 Tools 45

10.4 Cleaning the parts after disassembly 46

10.5 Assembly of the Device 46

11 FUNCTION TEST AFTER THE REPAIR 47

12 DISPOSAL 48

13 ACCESSORIES 50

13.1 Cobra 40-10 Accessories 50

13.2 Cobra 40-25 Accessories 52

14 SPARE PARTS 54

14.1 How can spare parts be ordered? 54

14.2 Overview of the Cobra 40-10 Components 55

14.3 Cobra 40-10 Air Motor 56

VERSION 01/2018 ORDER NUMBER DOC 2340851 Cobra 40-10 / 40-25

14.4 Cobra 40-10 Fluid Section 58

14.5 Overview of the Cobra 40-25 Components 61

14.6 Cobra 40-25 Air Motor 62

14.7 Cobra 40-25 64

14.8 Cobra 40-10 Inlet Valve 67

14.9 Inlet Valve Depressor 67

14.10 Cobra 40-25 Inlet Valve 68

14.11 Relief valve 68

14.12 High-pressure Filter (up to 530 bar; 7687 psi) 70

14.13 Inline Filter 90° (up to 270 bar; 3916 psi) 72

14.14 Straight Inline Filter (up to 270 bar; 3,916 psi) 73

14.15 AirCoat Regulator and AirCoat Filter Regulator 74

14.16 Cobra 40-10 Frame, Complete 75

14.17 Cobra 40-25 Frame, Complete 75

14.18 Horizontal Cobra Trolley 76

14.19 Sliding tables 78

14.20 Complete Hopper 79

14.21 2 Liter Tank 80

15 GUARANTEE AND CONFORMITY DECLARATIONS 81

15.1 Important notes on product liability 81

15.2 Warranty claim 81

15.3 EU Declaration of Conformity 82

VERSION 01/2018 ORDER NUMBER DOC 2340851 Cobra 40-10 / 40-25

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 operating 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 risk.

Non-observance can result in death or serious injury.

CAUTION Potentially hazardous situation.

Non-observance may result in minor injury.

NOTICE Potentially hazardous situation.

Non-observance may result in damage to property.

Notice Provides information about particular characteristics and

how to proceed.

Explanation of warning:

LEVEL OF DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

The measures for preventing the hazard and its consequences.

VERSION 01/2018 ORDER NUMBER DOC 2340851 Cobra 40-10 / 40-25

1.3 LANGUAGES

The operating manual is available in the following languages:

Original Operating Manual

Language Order No.

German 2340850

Translation of the Original Operating Manual

Language Order No. Language Order No.

French 2340852 Italian 2340853

Spanish 2340854 Russian 2345830

Japanese 2346196 Hungarian 2352542

English 2340851 -- --

Additional languages on request or at: www.wagner-group.com

1.4 ABBREVIATIONS

Order No. Order number Qty Number of pieces

ET Spare part DH Double stroke

K Marking in the spare parts lists SSt Stainless steel

Pos Position 2K Two components

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 ushing agent.

Product pressure

generator

Pump or pressure tank.

Sta 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

accordance with 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 areas of explosion protection, protection

from pressure hazards and electric hazards (if applicable) 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.

VERSION 01/2018 ORDER NUMBER DOC 2340851 Cobra 40-10 / 40-25

2 CORRECT USE

2.1 DEVICE TYPES

Double diaphragm pump and spray pack:

Cobra 40-10

Cobra 40-25

2.2 TYPE OF USE

The device is suitable for processing liquid products like paints and lacquers:

– Non-ammable products

– Products in accordance with the classication into explosion classes IIA or IIB (see

Chapter 2.4).

WAGNER explicitly prohibits any other use!

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.

2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

The device can be employed in explosion hazard zones (Zone 1) (see Chapter 3).

VERSION 01/2018 ORDER NUMBER DOC 2340851 Cobra 40-10 / 40-25

2.4 PROCESSIBLE WORKING MATERIALS

Fluid materials like paints and varnishes.

Application Cobra 40-10 Cobra 40-25

Water-dilutable products

Solvent-based lacquers and paints

Two-component coating products

Emulsions

UV lacquers

Primers

Epoxy and polyurethane lacquers, phenolic lacquers

Liquid plastics

Wax-based underside protection

Shear-sensitive lacquers

recommended limited suitability not suitable

NOTICE

Abrasive working materials and pigments!

Greater wear of parts carrying the product.

Use the application-oriented model (ow rate/cycle, product, valves, etc.) as

indicated in Chapter 5.5.

Check if the uids and solvents used are compatible with the pump construction

materials as indicated in Chapter 5.5.1.

Use suitable combinations of devices (packings, valves etc.)

Wear caused by abrasive working materials is not covered by the warranty.

Typical applications

Application Cobra 40-10 Cobra 40-25

Furniture industry

Kitchen manufacturers

Joinery

Window factories

Steel-processing industry

Construction of vehicles

Shipbuilding

recommended limited suitability not suitable

2.5 MISUSE

Misuse can lead to physical injury and/or property damage!

Special attention must be paid that:

no dry coating products, e.g. powder are processed.

no food, medicine or cosmetics are processed.

It is important to note that the device's materials are not food-safe.

VERSION 01/2018 ORDER NUMBER DOC 2340851 Cobra 40-10 / 40-25

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially

explosive areas.

Device types: Double diaphragm pumps Cobra 40-10 and Cobra 40-25

Manufacturer: Wagner International AG

CH-9450 Altstätten, Switzerland

CE European Communities

Ex Symbol for explosion protection

II Device class II

2 Category 2 (Zone 1)

G Ex-atmosphere gas

Ex Explosion protection

h Ignition protection for non-electrical devices

IIB Explosion group

T6 <85 °C

Gb High safety level

X Special notes (see Chapter 3.2)

See the following Chapter "Identication 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 5.5.2 (Technical

Data).

Safe handling of WAGNER spray devices

Mechanical sparks can form if the device comes into contact with metal.

In an explosive atmosphere:

Knocking or pushing metal against metal is to be avoided.

Do not drop the device.

Maximum surface temperature

The maximum surface temperature of the pump depends on the operating

conditions (heated product) and not on the device (frictional heat).

Ignition temperature of the coating product

Ensure that the ignition temperature of the coating product is above the maximum

surface temperature.

Ambient temperature

Permissible ambient temperature: 10 °C to 60 °C; 50 °F to 140 °F.

Medium supporting atomizing

To atomize the product, use only weakly oxidizing gases, e.g., air.

Surface spraying, electrostatics

Do not spray device parts using electrostatic equipment.

Cleaning

If there are deposits on the surfaces, the device may form electrostatic charges. Flames

or sparks can form during discharge.

Remove deposits from the surfaces to maintain conductivity.

Use only a damp cloth to clean the device.

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