Wagner SprayTech B-04234 User Manual
Translation of the Original
Operating Manual
Cobra 40-10
Version 10/2013
High-pressure
Double Diaphragm Pumps
B_04234
VERSION 10/2013
ORDER NUMBER DOC 2303675
OPERATING MANUAL
Table of Contents
1 ABOUT THIS OPERATING MANUAL 5
1.1 Preface 5
1.2 Warnings, Notices, and Symbols in this Operating Manual 5
1.3 Languages 6
1.4 Abbreviations in the Text 6
2 CORRECT USE 7
2.1 Device Types 7
2.2 Type of Use 7
2.3 Use in an Explosion Hazard Area 7
2.4 Safety Parameters 7
2.5 Processible Working Materials 8
2.5.1 Recommended Application Areas 8
2.6 Reasonably Foreseeable Misuse 9
2.7 Residual Risks 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identi cation 10
3.2 Identi cation X 10
4 GENERAL SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Equipment 11
4.1.2 Sta Quali cations 11
4.1.3 Safe Work Environment 11
4.2 Safety Instructions for Sta 12
4.2.1 Safe Handling of WAGNER Spray Devices 12
4.2.2 Grounding the Device 13
4.2.3 Product Hoses 13
4.2.4 Cleaning 14
4.2.5 Handling Hazardous Liquids, Lacquers and Paints 14
4.2.6 Touching Hot Surfaces 14
4.3 Use in Areas Subject to Explosion Hazards 15
4.3.1 Safety Regulations 15
4.3.2 Operation without Fluid 16
5 DESCRIPTION 17
5.1 Scope of Delivery 17
5.2 Data 17
5.2.1 Materials of Paint-wetted Parts 17
5.2.2 Technical Data 17
5.2.3 Measurements and Connections 19
5.2.4 Volume Flow 20
5.2.5 Performance Diagrams 20
5.3 Function 22
5.3.1 Pump 22
5.3.2 Pressure Regulator Unit for Cobra 24
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6 ASSEMBLY AND COMMISSIONING 25
6.1 Installation and Connection 25
6.1.1 Installing the Pump 25
6.1.2 Grounding 26
6.2 Commissioning 28
6.2.1 Safety Instructions 28
6.2.2 Basic Flushing 31
6.2.3 Filling with Working Material 32
7 OPERATION 33
7.1 Spraying 33
7.2 Work Interruption 33
7.3 Decommissioning and Cleaning 34
7.4 Long-term Storage 34
8 TROUBLESHOOTING, MAINTENANCE, AND REPAIR 35
8.1 Troubleshooting and Recti cation 35
9 MAINTENANCE 37
9.3 Hydraulic Stage Maintenance 38
9.3.1 Checking the Oil Level 38
9.3.2 Changing the Oil 39
10 ACCESSORIES 42
10.1 Cobra 40-10 Accessories 42
11 SPARE PARTS 44
11.1 How Can Spare Parts Be Ordered? 44
11.2 Overview of the Cobra 40-10 Components 45
11.3 Cobra 40-10 Air Motor 46
11.4 Cobra 40-10 Fluid Section 50
11.9 Cobra 40-10 Inlet Valve 54
11.10 Inlet Valve Depressor 54
11.11 Relief Valve 55
11.12 Cobra 40-10 Frame, Complete 56
11.13 Hopper, Complete 56
11.14 Trolley 57
11.16 Small Quantity Cup 58
12 3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING 59
12.1 Scope of Guarantee 59
12.2 Guarantee Period and Registration 59
12.3 Handling 59
12.4 Exclusion of Guarantee 60
12.5 Additional Regulations 60
12.3 CE Declaration of Conformity 61
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1 ABOUT THIS OPERATING MANUAL
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 operating and service
sta .
Operating and service sta should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
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 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
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.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard 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 following are measures which can be taken to prevent
the hazard 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 following are measures which can be taken to prevent
the hazard and its consequences.
Notice - a possibly hazardous situation.
Non-observance may result in material damage.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The following are measures which can be taken to prevent the hazard and its
consequences.
NOTICE
Note - provides information about particular characteristics and how to proceed.
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1.3 LANGUAGES
The operating manual is available in the following languages:
Language Order No. Language Order No.
German 2303152 English 2303675
French 2303676 Dutch 2303677
Italian 2303678 Spanish 2303679
Danish 2303680 Swedish 2303682
Portuguese 2343519
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
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2 CORRECT USE
2.1 DEVICE TYPES
Double diaphragm pump and spray pack:
2.2 TYPE OF USE
The device is suitable for processing liquid materials like paints and lacquers in accordance
with the classi cation into explosion classes IIA or IIB.
2.3 USE IN AN EXPLOSION HAZARD AREA
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 incorrect use.
Use the device only to work with the products recommended by WAGNER.
Only operate 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 on the basis of 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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2.5 PROCESSIBLE WORKING MATERIALS
Fluid products such as paints and lacquers.
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
Legend
recommended limited suitability less 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 5.2.2.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.2.1.
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
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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 10 of this operating manual.
The forms of misuse listed below may result in health issues and/or material 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
Paint in air outside
the de ned working
area
Handling of
lacquers and
cleaning agents
Painting outside the
de ned working
area
Skin irritations, Wear protective
clothing,
allergies observe safety data
sheets
Inhalation of
substances which
are hazardous to
health
Observe working
and operating
instructions
Operation,
maintenance,
disassembly
Operation,
maintenance
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3 IDENTIFICATION
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)
3.2 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.
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual to hand near the device at all times.
Always follow local regulations concerning occupational safety and accident prevention.
4.1.1 ELECTRICAL EQUIPMENT
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.
4.1.2 STAFF QUALIFICATIONS
Ensure that the device is operated and repaired only by trained persons.
4.1.3 SAFE WORK ENVIRONMENT
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 MOhm).
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 Mohm.
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5.
The measured insulation resistance must not exceed 100 Mohm.
Paint mist extraction 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 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.
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning 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 against actuation.
– In the event of functional faults: remedy the fault as described in the "Troubleshooting"
chapter.
The liquid ejection devices are to be checked for safe working conditions by an expert
(e.g. Wagner Service Technician) as often as necessary or at least every 12 months,
in accordance with the guidelines for liquid emitters (ZH1/406 and BGR500 Part 2
Chapter2.36).
– For devices that have been shut down, the inspection can be postponed until the next
commissioning.
Carry out the work steps as described in the "Pressure Relief/Work Interruptions" chapter:
– 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 cleaning agents:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through 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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4.2.2 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 dissipative gloves when spraying. The grounding takes place via the spray gun handle.
4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products.
Ensure that the product hose is suitable for the pressure generated in the device.
Ensure that the following information can be seen on the high-pressure hose:
– Manufacturer
– Permissible operating overpressure
– Date of manufacture
Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid
in the following places:
– in high-traffic areas,
– on sharp edges,
– on moving parts, or
– on hot surfaces
Make sure that the hoses are never used to pull or move the device.
The electrical resistance of the complete high-pressure hose must be less than 1 Mohm.
Several liquids have a high expansion coe cient. 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 suitable gas can enter
the tank to avoid a vacuum being generated in the tank itself. 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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4.2.4 CLEANING
De-energize the device electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the device.
Ensure that the flash point of the cleaning agent is at least 5 K above the ambient temperature.
To clean, use cloths and brushes moistened with solvent. Never use hard objects or spray
on cleaning agents with a gun.
Preferably, non-combustible cleaning agents should be used.
An explosive gas/air mixture forms in closed tanks.
When cleaning devices with solvents, never spray into a closed tank.
Only use electrically conductive tanks for cleaning liquids.
The tanks must be grounded.
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.
4.2.6 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:
- Identify the device with a warning label "Warning - hot surface".
Order No.
9998910 Instruction label
9998911 Protection sticker
Note: Order the two stickers together.
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4.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
The pneumatic pump may be used in potentially explosive areas. The following safety
regulations must be observed and followed.
4.3.1 SAFETY REGULATIONS
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.
Ignition temperature of the pumped product
Check that the ignition temperature of the pumped product is higher than the max.
allowable surface temperature.
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.
Only use a damp cloth to clean the device.
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4.3.2 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 smoothly, paying special attention to the
presence of air in the pumped uid, which may be caused by damaged packings.
Avoid operating the pump with damaged packings.
Ensure that the separating agent tank is lled with su cient separating agent.
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5 DESCRIPTION
5.1 SCOPE OF DELIVERY
Order No. Designation
2301858 1 Frame-mounted diaphragm pump Cobra 40-10 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 12.3 1 Conformity certi cate GM2000W
2303152 1 Operating manual, German
see Chapter 1 1 Operating manual in the local language
The delivery note shows the exact scope of delivery.
Accessories: see Chapter 10.
5.2 DATA
5.2.1 MATERIALS OF PAINTWETTED PARTS
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
5.2.2 TECHNICAL DATA
Description Devices
Pump ratio 40:1
Volume ow per double stroke (DH) cm 10
cu inch 0.6
Maximum operating overpressure MPa 25
bar 250
psi 3626
Maximum possible strokes in operation DH/min 200
Minimum/maximum air inlet pressure MPa 0.25-0.6
bar 2.5-6
psi 36.3-87
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Description Devices
Air inlet (inside thread) inch G 1/2
Minimum Ø of the compressed air supply line mm 13
inch 0.51
Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke NL 3.5
Sound pressure level at maximum permissible air pressure* dB(A) 74
Sound pressure level at 0.45 MPa; 4.5 bar; 65.27 psi
air pressure*
Sound pressure level at 0.3 MPa; 3 bar; 43.5 psi
air pressure*
Air motor piston diameter mm 80
Product inlet (outside thread) mm M36x2
Product outlet connection (inside thread) inch G 3/8"
Product outlet (outside thread) inch G 1/4"
Weight kg; lb 19; 41.9
Product pH value pH 3.5-9
Maximum product pressure at pump inlet MPa 2
Product temperature °C +10 ÷ +80
Ambient temperature °C +10 ÷ +60
Allowable inclination for operation
Hydraulic oil lling amount (approximate) L 0.110
dB(A) 72
dB(A) 69
inch 3.15
bar 20
psi 290
°F +50 ÷ +176
°F +50 ÷ +140
±10
cu inch 6.71
* 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).
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water (quality standard
5.5.4 according to ISO 8573.1) 5.5.4 = 40 m / +7 / 5 mg/m³.
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5.2.3 MEASUREMENTS AND CONNECTIONS
N
G
F
E
B
D
Cobra 40-10
P
O
Q
B_02943
Measurement
mm; inch
A 505; 19.88
B 313; 12.32
C 322; 12.68
D 134; 5.28
E 55; 2.16
F 182; 7.16
G 80; 3.15
HM6
I
25; 0.98
K G1/4"
L M36x2
M NPSM1/4-18
N 149; 5.87
O 91; 3.58
P 107; 4.21
Q 175; 6.89
R
7; 0.28
R
G
F
C
A
I
L
H
M
B_04235
K
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5.2.4 VOLUME FLOW
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
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.
5.2.5 PERFORMANCE DIAGRAMS
Stroke frequency (DH/min)
Example
BAR
BAR
BAR
Product pressure (bar)
"?
Water ow rate (nl/min)
BAR
BAR
BAR
Air consumption (nl/min)
20
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