VM 500
II 3 G
B_03416
VM 500
Electrostatic Control Unit
for Electrostatic Manual Spray Guns
Version 08/2014
Translation of the Original
Operating Manual
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VM 500
OPERATING MANUAL
EDITION 08/2014 ORDER NUMBER DOC2318724
Table of Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Preface 5
1.2 Warnings, Notices and Symbols in these Instructions 5
1.3 Languages 6
1.4 Abbreviations 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 an Explosion Hazard Area 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 Personnel 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 Material Hoses 16
4.2.4 Cleaning and Flushing 17
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 17
4.2.6 Touching Hot Surfaces 18
4.3 Protective and Monitoring Equipment 18
4.4 Use in Areas Subject to Explosion Hazards 18
4.4.1 Safety Regulations 18
5 DESCRIPTION 19
5.1 Design 19
5.2 Mode of Operation 19
5.3 Scope of Delivery 19
5.4 Technical Data 20
5.5 Operating Elements and Connections 21
5.5.1 Operating Elements Front Side 21
5.5.2 Connections on the Rear Side 22
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Table of Contents
6 ASSEMBLY AND COMMISSIONING 23
6.1 Training Assembly/Commissioning Sta 23
6.2 Storage Conditions 23
6.3 Installation Conditions 23
6.4 Additional Components 24
6.5 Location of the Control Unit 25
6.6 Grounding 26
6.7 Example, AirCoat Spraying System 28
6.8 Verifying a Safe Operational Condition 29
7 OPERATION 30
7.1 Training the Operating Sta 30
7.2 Safety Instructions 30
7.2.1 Emergency Deactivation 31
7.3 Starting Up and Spraying 31
7.4 Standby Mode 32
8 CLEANING AND MAINTENANCE 33
8.1 Cleaning 33
8.1.1 Cleaning Sta 33
8.1.2 Safety Instructions 33
8.2 Maintenance 35
8.2.1 Maintenance Sta 35
8.2.2 Safety Instructions 35
8.2.3 Safety Checks 36
9 TROUBLE SHOOTING AND RECTIFICATION 37
10 REPAIR WORK 38
10.1 Repair Sta 38
10.2 Safety Instructions 38
10.3 Check the Control Unit for Leak-Tightness 38
11 DISPOSAL 39
12 ACCESSORIES 40
13 SPARE PARTS 41
13.1 How Can Spare Parts Be Ordered? 41
13.2 Control Unit VM 500 42
14 WARRANTY AND CONFORMITY DECLARATIONS 44
14.1 Important Notes Regarding Product Liability 44
14.2 Warranty Claim 44
14.3 CE Declaration of Conformity 45
14.4 Notes on National Regulations and Guidelines 46
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OPERATING MANUAL
EDITION 08/2014 ORDER NUMBER DOC2318724
1 ABOUT THESE INSTRUCTIONS
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
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 personnel should be instructed according to the safety
instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
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1.3 LANGUAGES
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part
Stainless steel
Two components
The VM 500 operating manual is available in the following languages:
Language Order No. Language Order No.
German 2310485 English 2318724
French 2318725 Italian 2318726
Spanish 2318728
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
agent
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
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 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 TRBS1203(2010): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards,
and explosion protection (where applicable).
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OPERATING MANUAL
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2.1 DEVICE TYPE
2 CORRECT USE
Control Unit for controlling GM 5000EA or GM 5000EAC electrostatic spray guns.
WAGNER's electrostatic control unit VM 500 controls and regulates the high-voltage supply
to the GM 5000EA or GM 5000 EAC spray guns used to apply liquid coating media.
The VM 500 may only be operated together with the above-mentioned manual spray
guns. If the control unit is operated in combination with devices other than the abovementioned 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!
2.2 TYPE OF USE
Incorrect use!
Risk of injury and damage to the device.
Only connect original WAGNER GM 5000EA/GM 5000EAC spray
guns to the VM 500 control unit.
WARNING
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OPERATING MANUAL
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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 device 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.
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 AN EXPLOSION HAZARD AREA
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".)
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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OPERATING MANUAL
EDITION 08/2014 ORDER NUMBER DOC2318724
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 500 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
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 500 control unit:
- Spray gun GM 5000EA
- Spray gun GM 5000EAC
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VM 500
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
2309228
1
2
4
5
6
7
8
9
10
11
12
18
13
14
15
16
17
21
19 20
B_04390
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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 number
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.
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
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 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 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.
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).
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 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!
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 against 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 (ZH1/406 and BGR500
Part2 Chapter2.29 and 2.36).
- For shut down devices, the examination can be suspended until the next start-up.
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.
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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