WAGNER Cobra 40-10, Cobra 40-25 Translation Of The Original Operating Manual
B_04233
B_04234
High-pressure Double Diaphragm
Pumps
Version 07/2014
Translation of the Original
Operating Manual
3
OPERATING MANUAL
VERSION 07/2014
ORDER NUMBER DOC2340851
Table of Contents
1 ABOUT THIS MANUAL 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations in the Text 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 Use in Potentially Explosive Areas 8
2.4 Safety Parameters 8
2.5 Processible Working Materials 9
2.5.1 Recommended Application Areas 9
2.6 Reasonably Foreseeable Misuse 10
2.7 Residual Risks 10
3 IDENTIFICATION 11
3.1 Explosion Protection Identi cation 11
3.2 Identi cation X 11
3.3 Type Plates 12
4 GENERAL SAFETY INSTRUCTIONS 13
4.1 Safety Instructions for the Operator 13
4.1.1 Electrical Equipment 13
4.1.2 Sta Quali cations 13
4.1.3 Safe Work Environment 13
4.2 Safety Instructions for Sta 14
4.2.1 Safe Handling of WAGNER Spray Devices 14
4.2.2 Grounding the Device 15
4.2.3 Product Hoses 15
4.2.4 Cleaning and Rinsing 16
4.2.5 Handling Hazardous Liquids, Lacquers and Paints 16
4.2.6 Touching Hot Surfaces 17
5 DESCRIPTION 18
5.1 Design 18
5.2 Mode of Operation 18
5.2.1 General Information 18
5.2.2 Air Motor (4) 18
5.2.3 Protective and Monitoring Equipment 18
5.2.4 Fluid Section (9) 19
5.2.5 Positioning 19
5.3 Scope of Delivery 20
5.4 Data 20
5.4.1 Materials of Paint-wetted Parts 20
5.4.2 Technical Data 20
5.4.3 Measurements and Connections 22
5.4.4 Volume Flow 23
5.4.5 Performance Diagrams 23
5.5 Pressure Regulator Unit for Cobra 25
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6 ASSEMBLY AND COMMISSIONING 26
6.1 Training Assembly/Commissioning Sta 26
6.2 Storage Conditions 26
6.3 Installation Conditions 26
6.4 Transportation 26
6.5 Assembly and Installation 27
6.5.1 Ventilation of the Spray Booth 28
6.5.2 Air Supply 28
6.5.3 Product Supply 28
6.6 Grounding 29
6.7 Safety Checks 30
6.8 Commissioning 31
6.8.1 Safety Instructions 31
6.8.2 Preparation for Commissioning 32
6.8.3 Basic Flushing 32
6.8.4 Filling with Working Material 33
7 OPERATION 34
7.1 Training the Operating Sta 34
7.2 Safety Instructions 34
7.3 Emergency Deactivation 35
7.4 Work 36
7.5 Pressure Relief/Work Interruption 36
7.5.1 Pressure Relief/Work Interruption 36
8 CLEANING AND MAINTENANCE 38
8.1 Cleaning 38
8.1.1 Cleaning Sta 38
8.1.2 Safety Instructions 38
8.1.3 Cleaning and Flushing Device 39
8.1.4 Long-term Storage 39
8.2 Maintenance 40
8.2.1 Maintenance Sta 40
8.2.2 Safety Instructions 40
8.2.3 Safety Checks 41
8.2.3.1 Grounding check 41
8.2.3.2 High-Pressure Filter 41
8.2.3.3 Product Hoses, Tubes and Couplings 42
8.2.4 Hydraulic Stage Maintenance 43
8.2.5 Checking the Oil Level 43
8.2.6 Changing the Oil 44
9 TROUBLESHOOTING, MAINTENANCE, AND REPAIR 47
9.1 Troubleshooting and recti cation 47
10 REPAIR WORK 49
10.1 Repair Sta 49
10.2 Safety Instructions 49
10.3 Cleaning the Parts after Disassembly 50
11 FUNCTIONAL CHECK AFTER REPAIR 51
Table of Contents
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12 DISPOSAL 53
13 ACCESSORIES 54
13.1 Cobra 40-10 Accessories 54
13.2 Cobra 40-25 Accessories 56
14 SPARE PARTS 58
14.1 How Can Spare Parts Be Ordered? 58
14.2 Overview of the Cobra 40-10 Components 59
14.3 Cobra 40-10 Air Motor 60
14.4 Cobra 40-10 Fluid Section 63
14.5 Overview of the Cobra 40-25 Components 67
14.6 Cobra 40-25 Air Motor 68
14.7 Cobra 40-25 71
14.8 Cobra 40-10 Inlet Valve 75
14.9 Inlet Valve Depressor 75
14.10 Cobra 40-25 Inlet Valve 76
14.11 Relief Valve 77
14.12 High-pressure Filter (up to 530 bar; 7687 psi) 78
14.13 Inline Filter 90° (up to 270 bar; 3,916 psi) 80
14.14 Straight Inline Filter (up to 270 bar; 3,916 psi) 81
14.15 Cobra 40-10 Frame, Complete 82
14.16 Cobra 40-25 Frame, Complete 82
14.17 Trolley 83
14.18 Cobra Trolley Horizontal 84
14.19 Hopper, Complete 86
14.20 Small Quantity Cup 87
14.21 2L Tank 88
15 WARRANTY AND CONFORMITY DECLARATIONS 89
15.1 Important Notes Regarding Product Liability 89
15.2 Warranty Claim 89
15.3 CE Declaration of Conformity 90
15.4 Notes on German Regulations and Guidelines 90
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1 ABOUT THIS MANUAL
1.1 PREFACE
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
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 - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
Note - provides information about particular characteristics and how to proceed.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the danger and its consequences.
NOTICE
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 operating and service
sta .
The device may only be operated by trained sta and in compliance with this operating
manual. Operating and service sta 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.
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1.3 LANGUAGES
The operating manual is available in the following languages:
Language Order No. Language Order No.
German 2340850 English 2340851
French 2340852 Italian 2340853
Spanish 2340854 Russian 2345830
Japanese 2346196
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Double stroke
Stainless steel
Two components
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of ink-guiding 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 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.
In accordance with
TRBS 1203 (2010)
Additional languages on request or at:
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2 CORRECT USE
2.1 DEVICE TYPES
Double diaphragm pump and spray pack:
2.2 TYPE OF USE
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for processing liquid materials like paints and lacquers in accordance
with the classi cation into explosion classes IIA or IIB.
The double diaphragm pump can be employed in explosion hazard areas (Zone 1).
2.4 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from non-intended use.
Use the device only to work with the products recommended by WAGNER.
Operate only the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The double diaphragm pump may only be operated under the following conditions:
The operating sta must be trained based on this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must
be observed.
The statutory requirements and accident prevention regulation standards in the
country of use must be observed.
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Application
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
2.5.1 RECOMMENDED APPLICATION AREAS
Application
Furniture industry
Kitchen manufacturers
Joinery
Window factories
Steel-processing industry
Construction of vehicles
Shipbuilding
Legend
recommended limited suitability less suitable
Legend
recommended limited suitability less suitable
2.5 PROCESSIBLE WORKING MATERIALS
Fluid products such as paints and lacquers.
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 5.4.2.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.4.1.
NOTICE
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2.6 REASONABLY FORESEEABLE MISUSE
The following is prohibited:
coating work pieces which are not grounded,
unauthorized conversions and modi cations to the double diaphragm pump,
processing dry or similar coating products, and
using defective components, spare parts, or accessories other than those described
in Chapter 13 of this operating manual.
The forms of misuse listed below may result in physical injury or property damage:
use of powder as coating product and
incorrectly set values for processing.
Wagner double diaphragm pumps are not designed for pumping food.
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Speci c measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritations, wear protective
clothing,
operation,
allergies observe safety data
sheets
maintenance,
disassembly
Lacquer in air
outside the de ned
working area
Lacquering outside
the de ned working
area
Inhalation of
substances which
are hazardous to
health
Observe working
and operating
manuals
operation,
maintenance
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3.1 EXPLOSION PROTECTION IDENTIFICATION
As de ned in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially
explosive areas.
European Communities
Symbol for explosion protection
Device class II
Category 2 (Zone 1)
Ex-atmosphere gas
Explosion group
Constructional safety
Special Notes (see Chapter 3.2)
3 IDENTIFICATION
3.2 IDENTIFICATION X
X The maximum surface temperature corresponds to the permissible product
temperature. This and the permissible ambient temperature can be found in the
"Technical Data" chapter.
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
The permissible ambient temperature is: +10 °C to +60 °C; +50 °C to 140 °F.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device against steel or rusty iron.
Do not drop the device.
Only use tools that are made of a permitted material.
12
Pumpentyp/ Pump type/ Type de pompe
Max. Materialdruck/ Fluid pressure/ Pression fluid
Übersetzungsverhältnis/ Ratio/ Rapport
Fördermenge DH/ Delivery DS/ Débit CD
Max. Luftdruck/ Air pressure/ Pression d`air
Max. Temp. Material/ Fluid
Serie Nr. / Serie No. / N. serie
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
J. WAGNER AG
MADE IN SWITZERLAND
CH-9450 ALTSTÄTTEN
II 2G IIB c X
B_05038
40-10
25 MPa
40:1
10 ccm
0.6 MPa
80°C
SOM3001
Pumpentyp/ Pump type/ Type de pompe
Max. Materialdruck/ Fluid pressure/ Pression fluid
Übersetzungsverhältnis/ Ratio/ Rapport
Fördermenge DH/ Delivery DS/ Débit CD
Max. Luftdruck/ Air pressure/ Pression d`air
Max. Temp. Material/ Fluid
Serie Nr. / Serie No. / N. serie
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
J. WAGNER AG
MADE IN SWITZERLAND
CH-9450 ALTSTÄTTEN
II 2G IIB c X
B_05039
40-25
25 MPa
40:1
25 ccm
0.63 MPa
80°C
SOM3001
OPERATING MANUAL
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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.
Only use a damp cloth to clean the device.
Operation without Fluid
Avoid running the pump so that it sucks in air (without uid inside). The air, combined with
the vapor of ammable uids, can generate internal areas with an explosion hazard.
Periodically check that the pump is working, paying special attention to the presence of air
in the pumped uid, which may be caused by damaged diaphragms.
Avoid operating the pump with damaged diaphragms.
3.3 TYPE PLATES
Example for Cobra 40-10
1
2
3
4
5
6
7
8
Example for Cobra 40-25
1
2
3
4
5
6
7
8
1 Pump type
2 Max. product pressure
3 Pump ratio
4 Delivery rate
5 Max. air pressure
6 Max. temp. material/ uid
7 Serial No.
8 Read instruction manual
before use
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 STAFF QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual on hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient in uences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ensure that the device is operated, maintained and repaired only by trained sta .
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
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
100megohms.
Ensure that during spraying, persons wear static dissipative gloves. Grounding takes
place via the spray gun handle.
If protective clothing is worn, including gloves, it has to comply with EN1149-5. The
measured insulation resistance must not exceed 100 megohms.
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that the following components of a safe working environment are available:
– Product/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
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4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
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 all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun to prevent actuation.
- 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 should be checked
for safe working conditions by an expert (e.g., Wagner Service Technician) in accordance
with the guidelines for liquid ejection devices (ZH1/406 and BGR500 Part2 Chapter2.29
and 2.36).
- If devices have been decommissioned, the examination can be suspended until the
next start-up.
Follow the "Pressure Relief Procedure":
- If pressure relief is required.
- If the spraying work is interrupted or stopped.
- Before the device is cleaned on the outside, checked or serviced.
- Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun brie y in a position.
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4.2.3 PRODUCT HOSES
4.2.2 GROUNDING THE DEVICE
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, owing liquids, and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Ensure that the device is grounded for every spraying operation.
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.
Ensure that the hose material is chemically resistant to the sprayed products and the
used ushing agents.
Ensure that the product hose is 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
- At sharp edges
- On moving parts
- 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.
Make sure that the hoses are never used to pull or move the device.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 megohm.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coe cient. In some cases, their volume can rise with
consequent damage to tubes, 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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4.2.5 HANDLING HAZARDOUS LIQUIDS, LACQUERS AND PAINTS
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents and cleaning agents
being used.
Take the speci ed protective measures; in particular, make sure that you wear safety
goggles, protective clothing, and gloves, as well as skin protection cream if necessary.
Use a mask or a breathing apparatus if necessary.
For su cient 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.
4.2.4 CLEANING AND RINSING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non- ammable cleaning and ushing agents.
Observe the speci cations of the paint 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.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- 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:
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 gun. Cleaning the device must not damage it in any
way.
Ensure that no electrical component is cleaned with nor even immersed into solvent.
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4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109.4°F:
- Mark the device with a warning label "Warning – hot surface".
Order No.
9998910 Instruction label
9998911 Protection label
Note: Order the two labels together.
18
1
4
6
9
3
5
2
7
13
14
10
11
12
15
8
B_04237
Cobra 40-10
1
4
6
9
3
5
2
7
14
10
11
12
15
8
B_04238
Cobra 40-25
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5 DESCRIPTION
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
the 2 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.
5.1 DESIGN
1 Control housing with integrated silencer
2 Air pressure regulator
3 Ball valve
4 Air motor
5 Compressed air inlet
6 Mounting ange
7 Relief valve
8 Product outlet
9 Fluid section
10 Product inlet
11 Grounding connection
12 Pressure stage casing
13 Return socket
14 Valve depressor
15 Exhaust air cap
5.2 MODE OF OPERATION
5.2.1 GENERAL INFORMATION
5.2.2 AIR MOTOR 4
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).
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.
5.2.3 PROTECTIVE AND MONITORING EQUIPMENT
19
B_01205
"?
B_01207
OPERATING MANUAL
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The Cobra pump may only be operated in a horizontal or vertical
position as shown in the diagrams. Overhead operation is not
permitted.
Vertical positioning Horizontal positioning
Overhead positioning
Overpressure!
Risk of injury from bursting components.
Never change the safety valve setting.
WARNING
Overhead operation or storage (air motor with pressure regulator below)
Air could get into the hydraulic circuit, causing a malfunction.
Avoid overhead operation or storage at all costs.
Venting, see chapter 8.2.6 Oil change
NOTICE
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).
5.2.4 FLUID SECTION 9
5.2.5 POSITIONING
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5.3 SCOPE OF DELIVERY
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
Description Devices
Pump ratio 40:1 40:1
Volume ow per double stroke cm 10 25
cu inch 0.6 1.5
Maximum operating overpressure MPa 25 25
bar 250 250
psi 3626 3626
Maximum possible strokes in operation /min 200 200
Minimum/maximum air inlet pressure MPa 0.25-0.6 0.25-0.6
bar 2.5-6 2.5-6
psi 36.3-87 36.3-87
Order No. Designation
2329519 1 Diaphragm pump Cobra 40-10 consisting of:
Fluid section, air motor, connection elements
2329521 1 Frame-mounted diaphragm pump Cobra 40-10 consisting of:
Fluid section, air motor, connection elements
2329523 1 Diaphragm pump Cobra 40-25 consisting of:
Fluid section, air motor, connection elements
2329525 1 Frame-mounted diaphragm pump Cobra 40-25 consisting of:
Fluid section, air motor, connection elements
The standard equipment includes:
322981 1 Sign
236219 1 Grounding cable, complete
341434 1 Double open-end wrench
see Chapter 15.3 1 Declaration of Conformity
2340850 1 Operating manual, German
see Chapter 1.3 1 Operating manual in the local language
The delivery note shows the exact scope of delivery.
Accessories: see Chapter 13.
5.4 DATA
5.4.1 MATERIALS OF PAINTWETTED PARTS
5.4.2 TECHNICAL DATA
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* A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with
DINEN 14462: 2005.
Reference measurements have been made by SUVA (Swiss Accident Insurance Institute).
Description Devices
Air inlet (inside thread) inch G 1/2 G 1/2
Minimum Ø of the compressed air
supply line
mm 13 19
inch 0.51 0.75
Air consumption at 0.6 MPa; 6 bar;
87psi 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;
4.5bar; 65.27psi air pressure*
dB(A) 72 74
Sound pressure level at 0.3 MPa; 3bar;
43.5psi air pressure*
dB(A) 69 71
Air motor piston diameter mm 80 100
inch 3.15 4
Product inlet (outside thread) mm M36x2 M36x2
Product outlet connection (inside
thread)
inch G 3/8" G 3/8"
Product outlet (outside thread) inch G 3/8" G 3/8"
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 2 2
bar 20 20
psi 290 290
Product temperature °C 10 – 80 10 – 80
°F 50 – 176 50 – 176
Ambient temperature °C 10 – 60 10 – 60
°F 50 – 140 50 – 140
Allowable inclination for operation
±10 ±10
Hydraulic oil lling amount
(approximate)
L 0.11 0.13
cu inch 6.71 7.93
Outgoing air containing oil!
Risk of poisoning if inhaled.
Provide water-free and oil-free compressed air
WARNING
Quality standard 7.5.4 according to ISO 8573.1: 2010
7: Solid particles with mass concentration of 5-10 mg/m³
5: Air humidity: pressure dew point ≤ +7 °C
4: Oil content: ≤ 5 mg/m³
22
B_02943
G
P
Q
N
O
R
F
B
D
E
F
H
I
K
L
M
G
A
C
B_04235
Cobra 40-10
B_04236
B
D
E
F
H
I
L
G
A
C
Cobra 40-25
K
M
OPERATING MANUAL
VERSION 07/2014
ORDER NUMBER DOC2340851
5.4.3 MEASUREMENTS AND CONNECTIONS
Measurement
mm; inch 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; 5.28 134; 5.28
E 55; 2.16 55; 2.16
F 182; 7.16 182; 7.16
G 80; 3.15 80; 3.15
HM6M6
I
25; 0.98 25; 0.98
K G1/4" G1/4"
L M36x2 M36x2
M G 3/8"A G 3/8"A
N 149; 5.87 149; 5.87
O 91; 3.58 91; 3.58
P 107; 4.21 107; 4.21
Q 175; 6.89 175; 6.89
R
7; 0.28 7; 0.28
23
BAR
BAR
BAR
BAR
BAR
BAR
"?
OPERATING MANUAL
VERSION 07/2014
ORDER NUMBER DOC2340851
5.4.4 VOLUME FLOW
5.4.5 PERFORMANCE DIAGRAMS
Stroke frequency (
/min)
Product pressure (bar)
Air consumption (nl/min)
Water ow rate (nl/min)
Wagner AL nozzles Volume ow in l/min.*
inch mm Spray angle at at at
7 MPa 10 MPa 15 MPa
70 bar 100 bar 150 bar
1015 psi 1450 psi 2175 psi
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 /min.
Example
24
NL/mi
n
L/mi
n
B_01203
C
nl/min
<scfm>
bar (MPa)
<psi>
250 (25)
<3625>
200 (20)
<2900>
150 (15)
<2175>
100 (10)
<1450>
50 (5)
<725>
0
0
0.4
<0.1>
0.8
<0.2>
1.2
<0.3>
1.6
<0.4>
2
<0.5>
2.4
<0.6>
l/min
<gpm>
0
1000
<35>
800
<28>
600
<21>
400
<14>
200
<7>
0
40
80
120
160
200
240
A
A
B
B
C
B_02947
C
nl/min
<scfm>
bar (MPa)
<psi>
250 (25)
<3625>
200 (20)
<2900>
150 (15)
<2175>
100 (10)
<1450>
50 (5)
<725>
0
0
1
<0.26>
2
<0.53>
3
<0.79>
4
<1.06>
5
<1.32>
6
<1.59>
l/min
<USgpm>
0
1500
<53>
1200
<42>
900
<32>
600
<21>
300
<11>
0
40
80
120
160
200 240
A
A
B
B
C
OPERATING MANUAL
VERSION 07/2014
ORDER NUMBER DOC2340851
Diagram for Cobra 40-10
Stroke frequency ( /min)
Product pressure
Air consumption
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
Diagram for Cobra 40-25
Stroke frequency ( /min)
Product pressure
Air consumption
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
25
B_04300
2
3
1
4
5
B_04301
2
3
1
OPERATING MANUAL
VERSION 07/2014
ORDER NUMBER DOC2340851
5.5 PRESSURE REGULATOR UNIT FOR COBRA
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 motor is
vented (control pressure is still present).
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).
26
OPERATING MANUAL
VERSION 07/2014
ORDER NUMBER DOC2340851
6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF
Incorrect installation/operation!
Risk of injury and damage to the device.
The assembly and commissioning sta must have the technical
skills to safely undertake commissioning.
When assembling, commissioning and carrying out all work,
read and follow the operating manuals and safety regulations
for the additionally required system components.
WARNING
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 of vibrations
and with a minimum amount of dust. The device must be stored in enclosed 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).
6.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be in a range between 0 °C and 40 °C;
32and 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 or a crane.
27
B_04239
1
6
7
2
4
5
OPERATING MANUAL
VERSION 07/2014
ORDER NUMBER DOC2340851
6.5 ASSEMBLY AND INSTALLATION
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) as described in the operating
manual.
Note:
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 gun instructions.
Inclined ground!
Risk of accidents if the device rolls away/falls.
Position the trolley with the piston pump horizontally.
If the surface is inclined, position the feet of the trolley towards
the gradient.
Secure the trolley.
WARNING
28
OPERATING MANUAL
VERSION 07/2014
ORDER NUMBER DOC2340851
6.5.1 VENTILATION OF THE SPRAY BOOTH
Toxic and/or ammable vapor mixtures!
Risk of poisoning and burns
Operate the device in a spray booth approved for the working
materials.
– or –
Operate the device on an appropriate spraying wall with the
ventilation (extraction) switched on.
Observe national and local regulations for the outgoing air
speed.
WARNING
6.5.2 AIR SUPPLY
You must ensure that only dry, clean atomizing air is used in the spray gun. Dirt and
moisture in the atomizing air worsens the spraying quality and spraying pattern.
Hose connections
Risk of injury and damage to the device.
Do not exchange hose connections of product hose and air
hose.
WARNING
6.5.3 PRODUCT SUPPLY
Bursting hose, bursting threaded joints!
Danger to life from injection of product
Ensure that the hose material is chemically resistant to the
sprayed products.
Ensure that the spray gun, threaded joints, and product hose
between the device and the spray gun are suitable for the
pressure generated in the device.
Ensure that the following information can be seen on the high-
pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
DANGER