Page 1
Translation of the Original Operating Manual Version 07/2014 High Pressure Double Diaphragm Pump for 2 Component Products with Mixing Ratio 1:1 B_5076...
4.1.1 Electrical Equipment 4.1.2 Personnel Qualifi cations 4.1.3 Safe Work Environment Safety Instructions for Staff 4.2.1 Safe Handling of WAGNER Spray Devices 4.2.2 Grounding the Device 4.2.3 Product Hoses 4.2.4 Cleaning and Rinsing 4.2.5 Handling Hazardous Liquids, Varnishes and Paints 4.2.6...
Page 4
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL Table of Contents ASSEMBLY AND COMMISSIONING Training Assembly/Commissioning Staff Storage Conditions Installation Conditions Transportation Assembly and Installation 6.5.1 Ventilation of the Spray Booth 6.5.2 Air Supply 6.5.3 Product Supply Grounding Safety Checks Commissioning 6.8.1 Safety Instructions 6.8.2...
Page 5
DISPOSAL ACCESSORIES 13.1 Cobra 40-10/2K Accessories SPARE PARTS 14.1 How Can Spare Parts Be Ordered? 14.2 Overview of the Cobra 40-10/2K Components 14.3 Cobra 40-10 Air Motor 14.4 Cobra 40-10 Fluid Section 14.5 Cobra 40-10 Inlet Valve 14.6 Inlet Valve Depressor 14.7...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL ABOUT THESE INSTRUCTIONS 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 staff .
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL LANGUAGES The operating manual is available in the following languages: Language Order No. Language Order No. German 2349649 English 2349980 Italian 2349981 Additional languages on request or at: ABBREVIATIONS IN THE TEXT Number of pieces Position Marking in the spare parts lists Order No.
The double diaphragm pump can be employed in explosion hazard areas (Zone 1). 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 fi xtures.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL PROCESSIBLE 2K WORKING MATERIALS WITH MIXING RATIO 1:1 The double diaphragm pump is suitable for processing liquid 2K products Application Water-dilutable products Solvent-based lacquers and paints Emulsions UV lacquers Primers Epoxy and polyurethane lacquers, phenolic lacquers Liquid plastics Wax-based underside protection Shear-sensitive lacquers...
Wagner double diaphragm pumps are not designed for conveying food. RESIDUAL RISKS Residual risks are risks which cannot be ruled out even in the event of correct use.
The permissible ambient temperature is: +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. 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.
Periodically check that the pump is working, paying special attention to the presence of air in the pumped fl uid, which may be caused by damaged diaphragms. Avoid operating the pump with damaged diaphragms. TYPE PLATE Example for Cobra 40-10/2K 1 Pump type J. WAGNER AG 2 Max. product pressure CH-9450 ALTSTÄTTEN...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS 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 EQUIPMENT Electrical devices and equipment To be provided in accordance with the local safety requirements with regard to the operating mode and ambient infl uences.
When 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 (ZH 1/406 and BGR 500 Part 2 Chapter 2.29 and 2.36).
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 4.2.2 GROUNDING THE DEVICE In order to avoid electrostatic charging of the device, the device must be grounded. Friction, fl 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.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 4.2.4 CLEANING AND RINSING Relieve the pressure from the device. De-energize the device electrically. Preference should be given to non-fl ammable cleaning and fl ushing agents. Observe the specifi cations of the paint manufacturer. Ensure that the fl 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.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 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.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL WARNING Overpressure! Risk of injury from bursting components. Never change the safety valve setting. 5.2.4 FLUID SECTION (9) The fl uid section has been designed as a double diaphragm pump with exchangeable inlet and outlet valves.
SCOPE OF DELIVERY Order No. Designation U850.00CA Double diaphragm pump Cobra 40-10/2K consisting of: Fluid section, air motor and connection elements mounted on trolley. U850.00MA Double diaphragm pump Cobra 40-10/2K consisting of: Fluid section, air motor, connection elements and holder for wall mounting.
Page 21
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL Description Devices Air inlet (inside thread) inch G 1/2 Minimum Ø of the compressed air supply line inch 0.51 Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke Sound pressure level at maximum dB(A) permissible air pressure* Sound pressure level at 0.45 MPa;...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 5.4.4 VOLUME FLOW Wagner AL nozzles Volume fl ow in l/min.* inch mm Spray angle 7 MPa 10 MPa 15 MPa 70 bar 100 bar 150 bar 1015 psi 1450 psi 2175 psi 0.007...
Page 24
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL Diagram for Cobra 40-10/2K Stroke frequency ( /min) nl/min bar (MPa) NL/min <scfm> <psi> 250 (25) 1000 <3625> <35> 200 (20) <2900> <28> 150 (15) <2175> <21> 100 (10) <1450> <14> 50 (5) <725>...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL PRESSURE REGULATOR UNIT FOR COBRA 1 Pressure regulator 2 Ball valve 3 Pressure gauge 4 Compressed air Inlet 5 AirCoat fi lter regulator Cobra (accessories) The AirCoat fi lter regulator must be mounted vertically in all installation positions for the diaphragm pump (see assembly manual for Filter Regulator, order number 2328614).
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL ASSEMBLY AND COMMISSIONING TRAINING ASSEMBLY/COMMISSIONING STAFF WARNING Incorrect installation/operation! Risk of injury and damage to the device. The assembly and commissioning staff 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.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL ASSEMBLY AND INSTALLATION 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.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 6.5.1 VENTILATION OF THE SPRAY BOOTH WARNING Toxic and/or fl 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.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL GROUNDING WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks. Clean the piston pump only with a damp cloth. WARNING Heavy paint mist if grounding is insuffi cient! Danger of poisoning.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL Cable cross sections Pump 4 mm2; Paint tank 6 mm2; Conveyor 16 mm2; Booth 16 mm2; Spraying stand 16 mm2; Procedure: 1 Screw on grounding cable with eye. 2 Clamp the grounding cable clip to a grounding connection on site.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL COMMISSIONING 6.8.1 SAFETY INSTRUCTIONS Every time before starting up, the following points should be observed as laid down in the operating manual: - Observe all safety regulations in accordance with Chapter 4. - Carry out commissioning properly. WARNING High pressure spray jet! Danger to life from injecting paint or solvent.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 6.8.2 PREPARATION FOR COMMISSIONING NOTICE Impurities in the spraying system! Spray gun blockage. Flush the spray gun and paint supply with a suitable fl ushing agent before commissioning. 6.8.3 BASIC CLEANING Place empty tank (5a and 5b) under return tubes (4a and 4b). Place suction hoses (7a and 7b) in a tanks with solvent (6a and 6b).
Page 33
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL Note: During the fl ushing procedure, briefl y press both valve depressors (V). B_05081 B_05080...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 6.8.4 FILLING WITH WORKING MATERIAL Positions of the ball valve Open: working position Closed: The air motor can still be under pressure. Vent: Operating pressure in the air motor is vented (control pressure is still present). B_04301 Place suction hoses (7a and 7b) with return tubes (4a and 4b) in the tanks with working material...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualifi ed and fi t to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL EMERGENCY DEACTIVATION EMERGENCY STOP In case of unforeseen occurrences the ball valve (1) should be vented immediately and the return valves (2) should be opened. B_05077 Closed Set the valves to circulation (rotate clockwise) B_03118 B_04301...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL WORK Positions of the ball valve Open: working position Closed: The air motor can still be under pressure. Vent: Operating pressure in the air motor is vented (control pressure is still present). 1 Secure gun and place nozzle in the gun. B_04301 2 Slowly open the ball valve.
Page 38
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL WARNING High pressure spray jet! Danger to life from injecting paint or solvent. Never reach into the spray jet. Never point the spray gun at people. Consult a doctor immediately in the event of skin injuries caused by paint or solvent.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING STAFF Cleaning work should be undertaken regularly and carefully by qualifi ed and trained staff . They should be informed of specifi c hazards during their training. The following hazards may arise during cleaning work: - Health hazard from inhaling solvent vapors - Use of unsuitable cleaning tools and aids...
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.
In accordance with the guideline for liquid ejection devices (ZH 1/406 and BGR 500 Part 2 Chapter 2.29 and Chapter 2.36): - The liquid ejection devices should be checked by an expert (e.g. a Wagner service technician) for their safe working conditions as required and at least every 12 months.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 8.2.3 SAFETY CHECKS WAGNER recommends having all spraying devices checked annually by a technical expert (e.g., WAGNER service technician) for safety reasons. 8.2.3.1 GROUNDING CHECK Every day Before starting work, carry out a visual check to ensure that the grounding connection is...
– 6 years from the date of the hose crimping (see fi tting embossing). – 10 years from the date of the hose imprinting. Fitting Hose imprinting Meaning Meaning embossing Name / Wagner xxx bar Pressure Manufacturer Crimping date Date of yymm (year/month)
4 Screw in threaded plug (5) and tighten with 2 Nm; 1.5 lbft. NOTICE Using hydraulic oil Using the wrong hydraulic oil can cause a malfunction. Use only original hydraulic oil - Wagner Order No. 322912 (250 ml or 15 cu inch).
NOTICE Using hydraulic oil Using the wrong hydraulic oil can cause a malfunction. Use only original hydraulic oil - Wagner Order No. 322912 (250 ml or 15 cu inch). Discharging oil Procedure: Decommission and clean the device -> Chapter 8.1.3 up to and including point 6.
Page 46
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL CAUTION Environmental pollution caused by waste oil! Waste oil in the sewage network or spilled on the ground causes severe environmental damage. Groundwater pollution is liable to prosecution. Collect waste oil and bring it to a collection point. Waste oil is taken back by the seller when purchasing hydraulic oil.
Page 47
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL Vent Procedure: Turn the pump upside down. Remove threaded plug (5). Slowly start up (vent) the pump until no air bubbles appear from the oil suction fi tting. Oil level A in the oil tank has to be within the specifi ed markings (X). Screw in threaded plug (5) and tighten with 2 Nm;...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL TROUBLESHOOTING, MAINTENANCE, AND REPAIR TROUBLESHOOTING AND RECTIFICATION Problem Cause Remedy The pump does not work. Air motor does not work or stops. Open and close ball valve on the pressure regulator unit or briefl y disconnect compressed air supply.
Page 49
Loss of power due to severe There is a lot of condensation Install a water separator. icing. water in the air supply. If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.
In accordance with the guideline for liquid ejection devices (ZH 1/406 and BGR 500 Part 2 Chapter 2.29 and Chapter 2.36): - The liquid ejection devices should be checked by an expert (e.g. a Wagner service technician) for their safe working conditions as required and at least every 12 months.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 10.3 CLEANING THE PARTS AFTER DISASSEMBLY ATTENTION Please note: All reusable parts (except for the electrical components) should be cleaned thoroughly using a suitable cleaning agent. Spare parts may have safety-relevant properties. Defective parts, O-rings and seal sets must always be re-placed. WARNING Incompatibility of cleaning agent and working medium! Risk of explosion and danger of poisoning by toxic gases.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL FUNCTION TEST AFTER THE REPAIR After all repairs, the device must be checked for safe condition before recommissioning. The necessary scope of inspection and testing depends on the repair carried out and must be documented by the repair staff .
Page 53
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL Activities Aid tools 1.5 General Inspections Torque wrench Check tightening torque of various screws. Tighten hexagon screws M12x65 (40-10) or M16x80 (40-25) and Visual check input valve housing with the prescribed torque. (see Chapter 14) Check all threaded connections Empty device completely and relieve pressure Check function of frame or transport trolley.
Page 54
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL DISPOSAL When the equipment must be scrapped, please diff erentiate the disposal of the waste materials. The following materials have been used: - Stainless steel - Aluminum - Plastic - Carbide Consumable products (lacquers, adhesives, fl ushing and cleaning agents, solvents) must be disposed of in accordance with all applicable legal requirements.
Incorrect maintenance/repair! Risk of injury and damage to the device. Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply.
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 14.2 OVERVIEW OF THE COBRA 40-10/2K COMPONENTS Order No. Designation Air motor 3/53 Preassembled Cobra 40-10 fl uid section 322436 Air motor casing 322437 Pressure stage casing 322235 Hood 4 with air outlet...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 14.3 COBRA 40-10 AIR MOTOR Order No. Designation 9998718 Drive fastener 367318 Shoulder screw 4 9925033 Washer 367311 Hood 4 367319 Sound absorbing mat 4 9999152 Velcro fastener coating part 9999151 Velcro fastener adhesive part 367318 Shoulder screw 4 9925033...
Page 63
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 10-15 Nm; 7-11 lbft Cobra 40-10 20-25 Nm; 15-18 lbft 2-3 Nm; 1.5-2.2 lbft Do not dismount the piston B_04251...
Page 64
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL Order No. Designation 9971137 O-ring 9900316 Hexagon socket head cap screw M6x50 9907039 Hexagon socket head cap screw M6x80 9971313 O-ring 2341175 Manometer with air regulator 0-10 bar, G1/8" 2309972 Pressure regulator Distributor piece mini 4 9974166 O-ring 9904407...
Page 65
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL...
ORDER NUMBER DOC2349980 VERSION 07/2014 OPERATING MANUAL 14.4 COBRA 40-10 FLUID SECTION 29 59 30 31 B_04252 Notes: The piston rod (25) may only be mounted with the screwed-on assembly pin (108). Grease all o-rings and seals lightly with grease (111) before mounting them. Order No.
The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.
Identifi cation: EC Certifi cate of Conformity The CE certifi cate of conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 322890 15.4...
Page 80
Order No. 2349980 Edition 07/2014 Germany Phone Telefax E-mail Switzerland Phone Telefax More contact addresses on the internet at: Company/Locations/WAGNER worldwide Subject to changes without notice...
Need help?
Do you have a question about the Cobra 40-10/2K and is the answer not in the manual?
Questions and answers