WAGNER VM 5000 User manual

VM 5000
B_03269
II 3 G
Electrostatic Control Unit
for Electrostatic Manual Spray Guns
Version 08/2014
Translation of the Original
Operating Manual

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Table of Contents
1 ABOUT THIS 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
1.5 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 Use in Potentially Explosive Areas 9
2.4 Safety Parameters 9
2.5 Reasonably Foreseeable Misuse 10
2.6 Residual Risks 10
3 IDENTIFICATION 11
3.1 CE Explosion Protection Identication 11
3.2 Identication "X" 12
3.3 Type Plate 13
4 GENERAL SAFETY INSTRUCTIONS 14
4.1 Safety Instructions for the Operator 14
4.1.1 Electrical Equipment 14
4.1.2 Sta Qualications 14
4.1.3 Safe Work Environment 14
4.2 Safety Instructions for Sta 15
4.2.1 Safe Handling of WAGNER Spray Devices 15
4.2.2 Grounding the Device 16
4.2.3 Product Hoses 17
4.2.4 Cleaning and Flushing 17
4.2.5 Handling Hazardous Liquids, Lacquers and Paints 18
4.2.6 Touching Hot Surfaces 19
4.3 Protective and Monitoring Equipment 19
4.4 Use in Areas Subject to Explosion Hazards 19
4.4.1 Safety Regulations 19
5 DESCRIPTION 20
5.1 Design 20
5.2 Mode of Operation 20
5.3 Scope of Delivery 20
5.4 Technical Data 21
5.5 Operating Elements and Connections 22
5.5.1 Operating Elements Front Side 22
5.5.2 Connections on the Rear Side 24
6 ASSEMBLY AND COMMISSIONING 25
6.1 Training Assembly/Commissioning Sta 25
6.2 Storage Conditions 25
6.3 Installation Conditions 25
6.4 Additional Components 26
6.5 Location of the Control Unit 27

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6.6 Grounding 28
6.7 Example, AirCoat Spraying System 30
6.8 Verifying a Safe Operational Condition 31
7 OPERATION 32
7.1 Training the Operating Sta 32
7.2 Safety Instructions 32
7.2.1 Emergency Deactivation 33
7.3 Starting Up the Control Unit 33
7.4 Setting and Saving Recipes 34
7.4.1 Setting the High-voltage 35
7.4.2 Setting the Current Limitation 36
7.4.3 Display During Spraying 37
7.5 Standby Mode 38
7.6 Display "Perform service" 39
7.7 Device Conguration 40
7.7.1 Parameter Overview of Level 1 for Users 40
7.7.2 Access to the Device Conguration Mode 43
7.7.3 Setting Example "Parameter C11" 44
7.8 Operating Hours Counter/Service Display 46
7.8.1 Maintenance Counter Set Up and Reading 47
7.9 External Interface 48
8 CLEANING AND MAINTENANCE 50
8.1 Cleaning 50
8.1.1 Cleaning Sta 50
8.1.2 Safety Instructions 50
8.2 Maintenance 52
8.2.1 Maintenance Sta 52
8.2.2 Safety Instructions 52
8.2.3 Safety Checks 53
9 TROUBLESHOOTING AND RECTIFICATION 54
10 REPAIR WORK 56
10.1 Repair Sta 56
10.2 Safety Instructions 56
10.3 Check the Control Unit for Leak-Tightness 56
11 DISPOSAL 57
12 ACCESSORIES 58
13 SPARE PARTS 59
13.1 How Can Spare Parts Be Ordered? 59
13.2 Control unit VM 5000 60
14 WARRANTY AND CONFORMITY DECLARATIONS 62
14.1 Important Notes Regarding Product Liability 62
14.2 Warranty Claim 62
14.3 CE Declaration of Conformity 63
14.4 Notes on National Regulations and Guidelines 64
Table of Contents

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1 ABOUT THIS 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 - 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
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.
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
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part
Stainless steel
Two components
The VM 5000 operating manual is available in the following languages:
Language Order No. Language Order No.
German 2310484 English 2318718
French 2318719 Italian 2318720
Spanish 2318721
Additional languages on request or at:

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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agents
Flushing Internal ushing of ink-guiding parts with ushing agent
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential
dangers associated with improper behavior, as well as the
necessary protective devices and measures.
Electrically trained
person
Is instructed by an electrician in the tasks assigned to him/her,
the potential dangers 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
dangers based on his/her technical training, knowledge and
experience, and knowledge of the 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 area of electrostatic coating 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 the context of BGI 764
Additional requirements for skilled persons can also be
referred to in TRBS1203(2010): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards,
and explosion protection (where applicable).

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2 CORRECT USE
2.1 DEVICE TYPE
2.2 TYPE OF USE
WAGNER's electrostatic control unit VM 5000 controls and regulates the high-voltage
supply to the GM 5000EA or GM 5000EAC spray guns used to apply liquid coating media
and the high-voltage Universal cascade.
The VM 5000 may only be operated together with the above-mentioned manual spray
guns or the high-voltage Universal cascade. If the control unit is operated in combination
with devices other than the above-mentioned spray guns, the SIRA authorization (type
approval) ceases to be valid.
These electrostatic manual spray guns are suitable for spraying liquid products, in particular
coating products that follow AirCoat or Airspray techniques. Coating products containing
solvents of explosion class II A may be used.
WAGNER forbids any other use!
Control unit for controlling GM 5000EA or GM 5000EAC electrostatic spray guns and the
high-voltage Universal cascade.
Incorrect use!
Risk of injury and damage to the device.
Only connect original WAGNER GM5000EA/GM5000EAC spray
guns or die WAGNER high-voltage Universal cascade to the
VM5000 control unit.
WARNING

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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 device 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.
The control unit may only be operated if all parameters are set and all measurements/
safety checks have been carried out correctly.
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
The control unit is designed together with the spray gun in accordance with the
94/9/EC(ATEX) directive. The spray gun is suitable for use in potentially explosive areas in
zone 1 and the control unit in the zone 2 area.
(See Chapter 3 "Explosion Protection Identication".)
If the Wagner high-voltage Universal cascade is operated in connection with the VM 5000
control unit, the high-voltage cascade cannot be used in an Ex zone. However, the control
unit may be still used in the zone 2 area.
The "Restricted breathing" type of explosion protection is only guaranteed if all sealed
elements in the control unit are present and undamaged. During operation, all electric
connections of the control unit have to be tightly sealed with the corresponding plug
connectors or closing elements.

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2.5 REASONABLY FORESEEABLE MISUSE
2.6 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out 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
hazardous to health
Observe work and
operation instructions
Operation,
maintenance
The forms of misuse listed below may result in physical injury or property damage:
Use with non-authorized spray guns:
Coating work pieces which are not grounded;
Performing unauthorized conversions or modications to the device;
Using defective components, spare parts or accessories other than those described
in the "Accessories" chapter of this operating manual;
Working with incorrect settings.

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3 IDENTIFICATION
3.1 CE EXPLOSION PROTECTION IDENTIFICATION
The control unit is designed together with the spray gun in accordance with the
94/9/EC (ATEX) directive. The spray gun is suitable for use in potentially explosive areas in
zone 1 and the control unit in the zone 2 area.
VM 5000 control unit
European Communities
Notied body: PTB
Explosion-proof equipment
Device class II (not mining)
Eective in zone
Eective in zone 1
Ex-atmosphere gas
Number of type examination certicate
"X": see chapter 3.2
European Communities
Explosion-proof equipment
Device class II (not mining)
Category 3 device (suitable for zone 2)
Ex-atmosphere gas
Electrical device corresponds to ignition protection type
Ignition protection type "Restricted breathing"
Device class (Gas) IIA
Temperature class T4
Device protection level Gc

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3.2 IDENTIFICATION "X"
Notice
The EC Type Examination Certicate from SIRA can be found in the operating manual for
the spray gun. This certicate covers the control unit when used in conjunction with the
spray gun.
The manufacturer certies that the control unit can be used in zone 2.
Cable connections
Only the corresponding cables for the device may be used (see chapter 12 and operating
manual for the spray gun).
Permissible Device Combinations
The following spray guns may be connected to the VM 5000 control unit:
- Spray gun GM 5000EA
- Spray gun GM 5000EAC

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VM 5000
Typ / Type: VM 5000
115VAC - 230VAC
50Hz / 60Hz
2307317
max. 40W
J.WAGNER AG
Industriestrasse 22
CH - 9450 Altstätten
Made in Switzerland
Serie Nr.:
Serial No.:
Spannung:
Voltage:
Artikel Nr.:
Article No.:
Eingangsleistung:
Input Power:
Schutzklasse:
Protection Class:
Norm:
Standard: EN 50050
IP 54
Spannung:
Voltage:
Strom:
Current:
max. 20Vpp
max. 1,0A
Eingangsstrom:
Input Current: max. 0.5A
I
0
Main Switch
Nicht unter Spannung trennen! Do not disconnect under voltage!
Prim.
1.0 AT
0102 II (2) G
SIRA 11 ATEX 5374X
II 3 G
Ex nR IIA T4 Gc
1
2
4
5
6
7
8
9
10
11
12
18
13
14
15 22
16
17 21
19 20
B_04389
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3.3 TYPE PLATE
1 Identication for category 3 (zone 2)
2 Identication for category 2 (zone 1)
3 Test center
4 Device type
5 Article number
6 Serial No.
7 Input voltage
8 Input power
9 Input current
10 Protection class
11 Standard
12 Do not disconnect under voltage!
13 Primary fuse 1.0 ampere slow-acting
14 Mains supply switch
15 Gun connection
16 Maximum voltage
17 Maximum current
18 Grounding
19 Never spray device parts using electrostatic
equipment (electrostatic spray gun!).
20 Use only a damp cloth to clean the unit.
Remove deposits from the surfaces.
21 Do not dispose of used electrical equipment
with household refuse.
22 Interface

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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
Keep this operating manual on hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
Ensure that the device is operated, maintained and repaired only by trained sta.
4.1.3 SAFE WORK ENVIRONMENT
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (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
100megohms.
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 EN1149-5. The
measured insulation resistance must not exceed 100 megohms.
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
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. With open
housings, there is a danger from line voltage.
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 or are damaged.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Connect 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.

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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 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
by an expert (e.g. Wagner service technician) to ensure their safe operational condition
in accordance with the guidelines for liquid ejection devices (ZH1/406 and BGR500
Part2 Chapter2.29 and 2.36).
- If devices have been decommissioned, the examination can be suspended until the
next start-up.
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
Anyone tted with a pacemaker must not enter the high-voltage area!
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.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking tightness
of 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.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.

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Carry out the work steps as described in the "Pressure Relief" 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 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.
4.2.2 GROUNDING THE DEVICE
Friction, owing liquids, and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See chapter "Grounding".
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. Grounding takes place via the spray gun
handle.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.

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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
ushing agents used.
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.
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.
4.2.4 CLEANING AND FLUSHING
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).

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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.
Which cleaning agent is used to clean the spray gun depends on which parts of the
spray gun have to be cleaned and which product has to be removed.When cleaning the
spray gun, only use non-polar cleaning agents to prevent conductive residues on the
surface of the spray gun. Should it however, be necessary to use a polar cleaning agent,
all residues of this cleaning agent have to be removed by using a non-conductive and
non-polar cleaning agent, once the cleaning is nished.
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 wear safety goggles, protective
clothing and gloves, as well as skin protection cream if necessary.
Use a mask or 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.

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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°F:
- Identify the device with a warning label, "Warning – Hot surface".
Order No.
9998910 Instruction label
9998911 Protection label
Note: Order the two labels together.
4.3 PROTECTIVE AND MONITORING EQUIPMENT
Protective and monitoring equipment must not be removed, modied 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.
Surface spraying, electrostatics
Never spray device parts using electrostatic equipment (electrostatic spray gun!).
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.
4.4 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
The control unit may be used in potentially explosive areas.The following safety regulations
must be observed and followed.
4.4.1 SAFETY REGULATIONS
Observe safety instructions in Chapter 3.2.

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5 DESCRIPTION
5.1 DESIGN
The VM 5000 control unit supplies the control voltage for the spray gun, in which high-
voltage is subsequently produced. The set value for high-voltage and the spray current
limitation are adjusted on the control unit and can be saved in three dierent recipes. The
high-voltage supply is switched on and o via the trigger of the spray gun.
The special linear characteristic for high voltage ensures that if the spray gun is brought too
close to the work piece (or ground), the high voltage is reduced automatically to prevent
an accidental spark discharge.
Additionally, the VM 5000 control unit can be used as a universal high-voltage generator,
in combination with the high-voltage Universal cascade.
In addition, the VM 5000 control unit has a wide range of other functions, such as an
operating hours counter, service interval display, external approval, fault display and an
easy-to-use interface.
5.2 MODE OF OPERATION
Quantity Order No. Description
1 2310477 VM 5000 control unit
The standard equipment includes:
Quantity Order No. Description
1 241270 Mains cable with Stak200; 3 m; 9.8 ft
1 130215 Grounding cable 10 m; 32.8 ft
2 9951117 Delay-action fuse 1.0 AT
1 2310487 ES 5000 Declaration of Conformity, manual
1 2310484 VM 5000 operating manual, German
1 see 1.1 Operating manual in local language
The delivery note shows the exact scope of delivery.
5.3 SCOPE OF DELIVERY
The VM 5000 control unit, together with the matching GM5000EA or GM5000EAC spray
gun and other components, form an electrostatic manual spray system. An example of this
kind of spraying system can be found in Chapter 6.7.