Cobra 40-10
Cobra 40-25
High-pressure
Double Diaphragm Pumps
Version 01/2018
B_04234
B_04233
VERSION 01/2018
ORDER NUMBER DOC 2340851
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 identication 10
3.2 Identication "X" 10
3.3 Type plates 11
Cobra 40-10 / 40-25
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 Qualications 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
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VERSION 01/2018
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
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
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
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VERSION 01/2018
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
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
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
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VERSION 01/2018
ORDER NUMBER DOC 2340851
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:
Cobra 40-10 / 40-25
DANGER
WARNING
CAUTION
NOTICE
Notice
Explanation of warning:
Immediate risk of danger.
Non-observance will result in death or serious injury.
Potential risk.
Non-observance can result in death or serious injury.
Potentially hazardous situation.
Non-observance may result in minor injury.
Potentially hazardous situation.
Non-observance may result in damage to property.
Provides information about particular characteristics and
how to proceed.
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.
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VERSION 01/2018
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
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
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
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
Electrically trained
person
Electrician Can assess the work assigned to him/her and detect possible
Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
Pump or pressure tank.
associated with improper behavior as well as the necessary
protective devices and measures.
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.
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient 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.
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VERSION 01/2018
ORDER NUMBER DOC 2340851
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 classication 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.
Cobra 40-10 / 40-25
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device can be employed in explosion hazard zones (Zone 1) (see Chapter 3).
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VERSION 01/2018
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.
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
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.
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VERSION 01/2018
ORDER NUMBER DOC 2340851
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened 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 "Identication X".
Cobra 40-10 / 40-25
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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VERSION 01/2018
Air in the pump uid
Flammable gas mixtures can form if air reaches the pump uid.
Prevent the pump from taking in air and running dry.
If air has been taken in, x the leak. Then, ll slowly and in a controlled manner until
the air has escaped.
Air in the pumped uid can be caused by damaged diaphragms.
Avoid operating the pump with damaged diaphragms.
Periodically check that the pump is working smoothly, paying special attention to
the presence of air in the pumped uid.
Filling and emptying
Flammable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
3.3 TYPE PLATES
Example for Cobra 40-10
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
Wagner International AG
CH-9450 Altstätten
Made in Switzerland
1
Pumpentyp/ Pump type/ Type de pompe
2
Max. Materialdruck/ Fluid pressure/ Pression fluid
3
Übersetzungsverhältnis/ Ratio/ Rapport
Fördermenge DH/ Delivery DS/ Débit CD
4
Max. Luftdruck/ Air pressure/ Pression d`air
5
Max. Temp. Material/ Fluid
6
Baujahr - Serie Nr. / Year of manufacture - Serial No.
7
8
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
B_05038
2017-3001
Example for Cobra 40-25
Wagner International AG
CH-9450 Altstätten
Made in Switzerland
Pumpentyp/ Pump type/ Type de pompe
1
Max. Materialdruck/ Fluid pressure/ Pression fluid
2
Übersetzungsverhältnis/ Ratio/ Rapport
3
Fördermenge DH/ Delivery DS/ Débit CD
4
Max. Luftdruck/ Air pressure/ Pression d`air
5
Max. Temp. Material/ Fluid
6
Baujahr - Serie Nr. / Year of manufacture - Serial No.
7
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
8
2017-3001
II 2G Ex h IIB T6 Gb X
40-10
25 MPa
40:1
10 ccm
0.6 MPa
80°C
II 2G Ex h IIB T6 Gb X
40-25
25 MPa
40:1
25 ccm
0.63 MPa
80°C
Designation
1 Pump type
2 Max. product pressure
3 Pump ratio
4 Delivery rate
5 Max. air pressure
6 Max. temp. product/ uid
7 Model year - serial number
8 Read the operating manual
before use
B_05039
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VERSION 01/2018
ORDER NUMBER DOC 2340851
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 local regulations concerning occupational safety and accident
prevention.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform sta 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.
Cobra 40-10 / 40-25
4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or steam!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working are is static dissipative in accordance
withEN61340-4-1 (resistance must not exceed 100 M).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
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 product / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is
used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M.
Ensure that during spraying, persons wear electrically conductive gloves. The
grounding takes place via the spray gun handle or the trigger.
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. No smoking.
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VERSION 01/2018
Ensure that the pipe joints, hoses, equipment parts and connections are
permanently, technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking
tightness strength of the connections etc.).
- Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard 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 qualications.
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
In electrostatics applications: anyone who belongs to a risk group according to EMF
Directive 2013/35/EU (e.g. those with active implants), must not enter the highvoltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or steam!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with paint and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents, and cleaning
agents being used.
Take the specied 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 sucient health and environmental safety: Operate the device in a spray booth
or on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
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VERSION 01/2018
4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint
or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the 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.
If necessary or at least every 12 months, the liquid ejection devices must be
checked for safe working conditions by an expert (e.g. WAGNER Service Technician)
in accordance with the guidelines for liquid ejection devices (ZH 1/406 and DGUV
100-500 Chapters 2.29 and 2.36).
− For shut-down devices, the check can be postponed until the next start-up.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby the user can lose his
balance and injure himself during falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
4.2.3 GROUND THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the
spray gun handle or the trigger.
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VERSION 01/2018
4.2.4 PRODUCT HOSE
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure
generated.
Ensure that the following information can be seen on the high-pressure hose:
− manufacturer
− permissible operating pressure
− date of manufacture
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 lift trucks), or that the
hoses are never put under pressure from the outside in any other way.
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
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 equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 M.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coecient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can
enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
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VERSION 01/2018
4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ammable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure
that all equipment and resources (e.g., collection tank, funnel, transport cart) are
conductive or static dissipative and grounded.
Observe the specications of the lacquer manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with units containing aluminium or galvanized and zinc-plated parts. They
may react chemically thus producing an explosion danger.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that an explosive
mixture may temporarily exist inside the lines and components of equipment:
−depending upon the used coating product,
−depending on the ushing agent (solvent) used.
explosive mixture inside the lines and items of equipment.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects,
and never spray cleaning agents with a spray gun. Cleaning the device must not
damage it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F:
- Identify the device with a warning label "Warning – hot surface".
Order No.
9998910 Instruction label
9998911 Protection label
Note: Order the two stickers together.
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VERSION 01/2018
4.2.7 MAINTENANCE AND REPAIR
Hazard due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Use only WAGNER original spare parts and accessories.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in the 13 "Spare parts" chapter and 14
that are assigned to the unit.
Do not use any defective components.
Exclusively use accessories listed in Chapter 13 and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
- Relieve the pressure from the spray gun, high-pressure hoses and all devices.
- Secure the spray gun against actuation.
– Switch o the energy and compressed air supply.
- Disconnect the control unit from the mains. Secure the spray gun against
actuation.
Observe the operating and service manual for all work.
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied 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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VERSION 01/2018
2
1
4
6
9
3
5
2
7
14
10
11
12
15
8
B_06834
Cobra 40-25
13
5 DESCRIPTION
5.1 COMPONENTS
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
Designation
1 Control housing with
Cobra 40-10
1
integrated silencer
2 Air pressure regulator
3 Ball valve
4 Air motor
5 Compressed air Inlet
6 Mounting ange
7 Relief valve
4
6
7
8
3
9
10
14
8 Product outlet
9 Fluid section
10 Product inlet
11 Grounding connection
5
12 Pressure stage casing
13 Return socket
14 Valve depressor
15 Exhaust air cap
B_06833
11
12
15
5.2 MODE OF OPERATION
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), up
and down. At the end of each stroke the compressed air is redirected by a reversing valve
and the control piston. The up-and-down movement of both diaphragms within the uid
section is produced by hydraulic oil, which is moved by the piston in the pressure stage.
With every stroke of the piston rod, working material is sucked in and delivered to the
spray gun at the same time.
5.2.1 AIR MOTOR
The air motor with its pneumatic reverse (1) does not require pneumatic oil. The compressed
air is fed to the motor via the air pressure regulator (2) and the ball valve (3).
5.2.2 FLUID SECTION
The uid section has been designed as a double diaphragm pump with exchangeable
inlet and outlet valves. Change between "spraying mode" and "circulation mode" using
the relief valve (7).
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VERSION 01/2018
5.3 PROTECTIVE AND MONITORING EQUIPMENT
WARNING
Overpressure!
Danger to life from bursting components.
Never change the safety valve setting.
The air motor is tted with a safety valve. The safety valve has been set and sealed at the
factory. In case of pressures over and above the permissible operating pressure, the valve,
which is held with a spring, automatically opens and releases the excess pressure.
5.4 INCLUDED ITEMS
Order No. Designation
1 2329519
1 2329521
1 2329523
1 2329525
The standard equipment includes:
Order No. Designation
1 322981 Sign
1 236219 Grounding cable, complete
1 341434 Double open-end wrench
1 see Chapter 15.2 Declaration of Conformity
1 2340850 Operating manual, German
1 see Chapter 1.3 Operating manual in the local language
The delivery note shows the exact scope of delivery. Accessories: see Chapter 13.
Diaphragm pump Cobra 40-10 consisting of:
Fluid section, air motor, connection elements
Frame-mounted diaphragm pump Cobra 40-10 consisting of:
Fluid section, air motor, connection elements
Diaphragm pump Cobra 40-25 consisting of:
Fluid section, air motor, connection elements
Frame-mounted diaphragm pump Cobra 40-25 consisting of:
Fluid section, air motor, connection elements
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
5.5 DATA
5.5.1 MATERIALS OF PAINT WETTED PARTS
Paint-wetted parts Product
Inlet housing Consital (aluminum alloy)
Fluid section Consital (aluminum alloy)
Valve balls Stainless steel
Valve seats/valve cone Carbide
Diaphragms Resistant PA
Valve tting 1.4104
19
VERSION 01/2018
5.5.2 TECHNICAL DATA
Description Units Cobra 40-10 Cobra 40-25
Pump ratio 40:1 40:1
Volume ow per double stroke (DH) cm
Maximum operating overpressure MPa
Maximum possible strokes in operation DH/min 200 200
Minimum/maximum air inlet pressure MPa
Compressed air quality: free from oil and water
Air inlet (inside thread) inch G 1/2“ G 1/2“
Minimum Ø of the compressed air supply line mm
Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke NL 3.5 8.3
Sound pressure level at maximum permissible air pressure* dB(A) 74 76
Sound pressure level at 0.45 MPa; 4.5 bar; 65.27 psi air pressure* dB(A) 72 74
Sound pressure level at 0.3 MPa; 3 bar; 43.5 psi air pressure* dB(A) 69 71
Air motor piston diameter mm
Product inlet (outside thread)
Product outlet (inside thread)
Product outlet (outside thread)
Weight kg; lb 19; 41.9 33; 72.8
Product pH value pH 3.5–9 3.5–9
Maximum product pressure at pump inlet MPa
Product temperature °C
Ambient temperature °C
Allowable inclination for operation ±10 ±10
Hydraulic oil lling amount (approximate) L
*A-rated sound pressure level measured at 1 m distance, LpA1m, according to DIN EN 14462: 2015.
Reference measurements have been made by SUVA (Swiss Accident Insurance Institute).
ORDER NUMBER DOC 2340851
Quality standard 7.5.4 according to ISO 8573.1,
2010
cu inch
bar
psi
bar
psi
inch
inch
mm
inch
inch
bar
psi
°F
°F
cu inch
10
0.6
25
250
3626
0.25–0.6
2.5–6
36.3–87
7: Particle concentration 5–10mg/
m
5: Humidity: pressure dew point ≤
7 °C
4: Oil content ≤ 5mg/m
13
0.51
80
3.15
M36×2
G 3/8“
G 3/8“
2
20
290
10–80
50–176
10–60
50–140
0.110
6.71
25
1.5
25
250
3626
0.25–0.6
2.5–6
36.3–87
19
0.75
100
4
M36×2
G 3/8“
G 3/8“
2
20
290
10–80
50–176
10–60
50–140
0.130
7.93
Cobra 40-10 / 40-25
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water.
20
VERSION 01/2018
B
D
E
F
H
I
K
L
M
G
A
C
B_04235
Cobra 40-10
T
P
ORDER NUMBER DOC 2340851
5.5.3 DIMENSIONS AND CONNECTIONS
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; 2.16
F 182; 7.16
G 80; 3.15
H M6
I 25; 0.98
K G1/4"
L M36×2
M G 3/8"A
N 149; 5.87
O 91; 3.58
P 107; 4.21
Q 175; 6.89
R 7; 0.28
S 525; 20.67 644; 25.35
T 367; 14.45 417; 16.42
U 275; 10.83
Cobra 40-10 / 40-25
E
B
D
Cobra 40-25
M
C
G
I
H
B_04236
N
F
Q
O
R
B_02943
G
Cobra 40-10
S
T
B_06937
U
K
Cobra 40-25
F
A
L
S
U
21
VERSION 01/2018
5.5.4 VOLUME FLOW
Wagner AL nozzles Volume ow in l/min.*
inch mm Spray angle at at at
0.007 0.18 40° 0.1650 0.2000 0.2400
0.009 0.23 20-30-40-50-60° 0.2060 0.2500 0.3090
0.011 0.28 10-20-30-40-50-60° 0.2950 0.3450 0.4260
0.013 0.33 10-20-30-40-50-60-80° 0.4530 0.5280 0.6600
0.015 0.38 10-20-30-40-50-60-80° 0.5770 0.6720 0.8130
0.017 0.43 20-30-40-50-60-70° 0.7310 0.7860 1.0640
0.019 0.48 20-30-40-50-60-70-80° 0.9260 1.0920 1.3700
0.021 0.53 20-40-50-60-80° 1.1430 1.3600 1.6900
0.023 0.58 20-40-50-60-70-80° 1.3700 1.5900 2.0100 Cobra 40-10
0.025 0.64 20-40-50-60-80° 1.6200 1.9100 2.4000
0.027 0.69 20-40-50-60-80° 1.8300 2.1300 2.6800
0.029 0.75 60° 2.1900 2.5100 3.1700
0.031 0.79 20-40-50-60° 2.4000 2.7700 3.4900
0.035 0.90 20-40-50-60° 3.2200 3.7400 4.6900 Cobra 40-25
0.043 1.10 20-50° 5.0700 6.0400 7.4600
0.052 1.30 50° 5.1200 6.5000 7.5200
Volume ow refers to water.
− Maximum ranges for continuous operation at 200 DH/min.
ORDER NUMBER DOC 2340851
7 MPa 10 MPa 15 MPa
70 bar 100 bar 150 bar
1015 psi 1450 psi 2175 psi
Cobra 40-10 / 40-25
22
VERSION 01/2018
NL/min
L/min
B_01203
100 (10)
<1450>
<USgpm>
ORDER NUMBER DOC 2340851
5.5.5 PERFORMANCE DIAGRAMS
Example
Stroke frequency (DH/min)
8 bar
Cobra 40-10 / 40-25
8 bar
6 bar
4 bar
Product pressure (bar)
B_00301
Cobra 40-10
bar (MPa)
<psi>
0
250 (25)
<3625>
200 (20)
<2900>
150 (15)
<2175>
100 (10)
<1450>
50 (5)
Product pressure
<725>
0
0
A = 6 bar (0.6 MPa; 87 psi) air pressure
B = 4.5 bar (0.45 MPa; 65 psi) air pressure
C = 3 bar (0.3 MPa; 44 psi) air pressure
Water ow rate (nl/min)
Stroke frequency (DH/min)
40
80
120
160
200 240
A
B
0.4
<0.1>
C
0.8
1.2
<0.2>
<0.3>
1.6
<0.4>
C
2
<0.5>
Water ow rate
B
6 bar
4 bar
A
2.4
<0.6>
Air consumption (nl/min)
nl/min
<scfm>
1000
<35>
800
<28>
600
<21>
400
<14>
Air consumption
200
<7>
0
l/min
<gpm>
Cobra 40-25
bar (MPa)
<psi>
250 (25)
<3625>
200 (20)
<2900>
150 (15)
<2175>
Product pressure
50 (5)
<725>
B_02947
0
Stroke frequency (DH/min)
40
0
0
1
<0.26>
80
120
A
B
C
2
3
<0.53>
<0.79>
160
4
<1.06>
Water ow rate
A = 6 bar (0.6 MPa; 87 psi) air pressure
B = 4.5 bar (0.45 MPa; 65 psi) air pressure
C = 3 bar (0.3 MPa; 44 psi) air pressure
200 240
B
C
5
<1.32>
A
6
<1.59>
nl/min
<scfm>
1500
<53>
1200
<42>
900
<32>
600
<21>
300
<11>
0
l/min
Air consumption
23
VERSION 01/2018
ORDER NUMBER DOC 2340851
5.6 COBRA PRESSURE REGULATOR UNIT
Designation
1 Pressure regulator
2 Ball valve
3 Pressure gauge
4 Compressed air Inlet
5 AirCoat lter regulator Cobra
(accessories)
The AirCoat lter regulator must be mounted
vertically in all installation positions for the
diaphragm pump (see assembly manual for
Filter Regulator, order number2328614).
Cobra 40-10 / 40-25
1
5
2
3
4
B_04300
Positions of the ball valve
1 Open: working position
2 Closed: the air motor can still be
under pressure.
3 Vent: Operating pressure in the air
3
motor is vented (control pressure is
still present).
2
1
5.6.1 HIGHPRESSURE FILTER OPTION
To ensure problem-free operation it is recommended that a WAGNER high-pressure lter
be used. These have been developed especially for WAGNER pneumatic pumps. The lter
inserts can be exchanged depending on the product to be used. The high-pressure lter
corresponding to the device can be found in Chapter; 13 and the compatible lter inserts
can be found in Chapter 14
B_04301
B_06835
24
VERSION 01/2018
ORDER NUMBER DOC 2340851
6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING OF ASSEMBLY/COMMISSIONING STAFF
The assembly and commissioning sta must have the technical skills to safely
commission the device.
When assembling, commissioning and carrying out all work, read and follow the
operating manuals and safety regulations for the additionally required system
components.
A skilled person must check to ensure that the device is in a reliable state after it is installed
and commissioned.
6.2 STORAGE CONDITIONS
Until the point of assembly, the device must be stored in a dry location, free from vibrations
and with a minimum of dust. The device must be stored in closed rooms.
The air temperature at the storage location must be between -20 °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).
Cobra 40-10 / 40-25
6.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be in a range between 0 °C and 40 °C; 32
°F and 132 °F.
The relative air humidity at the installation site must be between 10 and 95% (without
condensation).
6.4 TRANSPORTATION
The pump can be moved on a trolley or manually without lifting equipment.
25
VERSION 01/2018
B_01205
B_01206
×
×
6.5 ASSEMBLY AND INSTALLATION
WARNING
Inclined ground!
Risk of accidents if the device rolls away/falls.
Position the trolley with the double diaphragm pump horizontally.
If the surface is inclined, position the feet of the trolley towards the gradient.
Secure the trolley.
National regulations
Ensure that the national explosion prevention rules and regulations are observed
when setting up the device.
Positioning
The Cobra pump may only be operated in a horizontal or vertical position as shown in the
diagrams. Overhead operation is not permitted.
ORDER NUMBER DOC 2340851
Cobra 40-10 / 40-25
B_06832
Horizontal positioning
This pump can be used as part of a spraying system for Airless or AirCoat applications. The
components can be found in the accessories list, provided that the system was not obtained
as a spray pack. The nozzles must be selected according to the spray gun instructions.
Procedure
1. Mount the pump on a frame,
trolley (6), or wall mount.
2. For AirCoat systems: Mount the
additional lter pressure regulator
(7) (option).
3. Mount suction system (5).
4. Mount return hose (4) (option).
5. Connect high-pressure hose and
spray gun (2) according to the
operating manual.
Vertical positioning
2
Overhead positioning
6
7
1
4
5
B_04239
26
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