VM 5000
B_03269
c
us
Electrostatic Control Unit
for Electrostatic Manual Spray Guns
Version 07/2014
Translation of the Original
Operating Manual
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VM 5000
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344501
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 Type 7
2.2 Type of Use 7
2.3 Safety Parameters 7
2.4 Reasonably Foreseeable Misuse 8
2.5 Residual Risks 8
3 IDENTIFICATION 9
3.1 Explosion Protection According to FM 9
3.2 Permissible Device Combinations 9
3.3 Notes to German Regulations and Guidelines 9
4 GENERAL SAFETY INSTRUCTIONS 10
4.1 Safety Instructions for the Operator 10
4.1.1 Electrical Equipment 10
4.1.2 Sta Quali cations 10
4.1.3 Safe Work Environment 11
4.2 Safety Instructions for Sta 11
4.2.1 Safe Handling of WAGNER Spray Devices 12
4.2.2 Grounding the Device 12
4.2.3 Material Hoses 13
4.2.4 Cleaning 13
4.2.5 Handling Hazardous Liquids, Lacquers and Paints 14
4.2.6 Touching Hot Surfaces 14
4.3 Correct Use 14
4.4 Safety Information on Discharges 15
4.5 Protective and Monitoring Equipment 15
5 DESCRIPTION 16
5.1 Areas of Application 16
5.2 Functional Description 16
5.3 Technical Data 16
5.4 Scope of Delivery 17
5.5 Operating Elements and Connections 18
5.5.1 Operating Elements Front Side 18
5.5.2 Connections on the Rear Side 20
6 COMMISSIONING AND OPERATION 21
6.1 Training Assembly/Commissioning Sta 21
6.2 Storage Conditions 21
6.3 Installation Conditions 21
6.4 Additional Components 22
6.5 Placement of the Device 23
6.6 Grounding 24
6.7 Example: AirCoat Spraying System 26
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Table of Contents
6.8 Device Con guration 28
6.8.1 Parameter Overview of Level 1 for Users 28
6.8.2 Access to the Device Con guration Mode 30
6.8.3 Setting Example "Parameter C11" 31
6.9 Operating Hours Counter / Service Display 33
6.9.1 Maintenance Counter Set Up and Reading 34
6.10 External Interface 35
7 OPERATION 37
7.1 Training the Operating Sta 37
7.2 Safety Instructions 37
7.3 Control Unit Start Up 38
7.4 Setting and Saving Recipes 39
7.4.1 Setting the High-voltage 40
7.4.2 Setting the Current Limiting 41
7.4.3 Display During Spraying 42
7.5 Standby Mode 43
7.6 Display "Conduct Service" 44
8 TROUBLESHOOTING AND RECTIFICATION 45
9 MAINTENANCE AND REPAIR 47
9.1 Maintenance 47
9.2 Repair 47
10 PRODUCT DISPOSAL 47
11 ACCESSORIES 48
12 SPARE PARTS 49
12.1 How Can Spare Parts Be Ordered? 49
12.2 Spare Parts List VM 5000 50
13 WARRANTY 52
13.1 Important Notes Regarding Product Liability 52
13.2 Warranty Claim 52
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1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
1 ABOUT THIS OPERATING MANUAL
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.
1.1 PREFACE
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 material damage.
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 following are measures which can be taken to prevent
the hazard 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 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
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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 operating manual is available in the following languages:
German English 2344501
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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 FM authorizations (type
approvals) cease 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.
Control unit for controlling GM 5000EA or GM 5000EAC electrostatic spray guns and the
high-voltage Universal cascade.
Incorrect use!
Risk of injury and equipment damage.
Only connect original Wagner spray guns or the high-voltage
Universal cascade to the VM 5000 control unit.
Only connect the GM 5000EA, GM 5000EAC spray guns or the
high-voltage Universal cascade.
WARNING
2.3 SAFETY PARAMETERS
The control unit is only suitable for controlling spray guns and the Wagner high-voltage
Universal cascade. J. Wagner AG forbids any other use!
The control unit may only be operated under the following conditions:
The operating sta have previously been 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 are carried out correctly.
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2.4 REASONABLY FORESEEABLE MISUSE
Coating work pieces which are not grounded
Use of defective components, spare parts or accessories
Use with non-authorized spray guns
2.5 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
solvent-based
paints and cleaning
agents
Handling of solventbased paints and
cleaning agents
Skin irritations, Wear protective
clothing,
Operation,
allergies observe safety data
sheets
maintenance,
disassembly
Solvent-based paint
in air outside the
de ned working
area
Painting outside the
de ned working
area
Inhalation of
substances
hazardous to health
Observe work and
operation instructions
Operation,
maintenance
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VM 5000
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OPERATING MANUAL
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The following spray guns may be connected to the VM 5000 control unit:
GM 5000EA spray gun
GM 5000EAC spray gun
Other gun types may only be connected to the control unit after rst checking their suitability
with Wagner.
3.2 PERMISSIBLE DEVICE COMBINATIONS
3.3 NOTES TO GERMAN REGULATIONS AND GUIDELINES
3.1 EXPLOSION PROTECTION ACCORDING TO FM
This device has been manufactured and tested by FM, according to the FM (Factory Mutual)
standard "Class Number 7260" (Approval Standard for Electrostatic Finishing Equipment).
All tested combinations of devices including accessories are given in the FM Control
Document with part number 2316160.
Authorization (type approval) of FM for class 1, div. 1 (spray gun)
For Electrostatic Finishing Applications using Class I, Group D,
Spray Material
In accordance with 2316160
Electrical devices and equipment
Part 2, Chapter 2.36 Working with Liquid Ejection Devices
Part 2, Chapter 2.29 Working with Coating Products
Explosion protection rules
Avoiding ignition risks
Equipment for cleaning work pieces with solvents
Guidelines for liquid ejection devices
Painting rooms and equipment
Electrostatic coating
Plant Safety Ordinance
Note: All titles can be ordered from Heymanns Publishing House in Cologne,
or they can be found on the Internet.
3 IDENTIFICATION
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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 at 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.
Control units
Place the control unit outside the spray booth / spray zone.
If possible, place the control unit outside the explosion zone (placement in Ex Zone2 is
permissible).
Protect the control unit from extreme temperature and moisture changes.
Protect the control unit from contamination.
Lay and x the connecting cable correctly.
Ensure that the local mains voltage and tension of the device match.
Ensure that the device is operated and repaired only by trained persons.
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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
100Mohm.
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.
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.
Under no circumstances may people with pacemakers enter the area where the
high-voltage eld between the spray gun and the work piece to be coated builds up!
Control units
When commissioning and for all work, read and follow the operating manual and safety
regulations for the additionally required system components.
Do not open the control unit.
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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 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 Part2
Chapter2.36).
– For shut down devices, the examination can be suspended 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 rm footing when operating the spray gun.
Only hold the spray gun brie y in a position.
4.2.2 GROUNDING THE DEVICE
Depending on the high-voltage on the spray electrode and the ow speed during spraying,
an electrostatic charge may occur in the device. This may result in the formation of sparks
or ames when discharging.
Ensure that the device is grounded at all times.
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 for grounding via the spray gun handle when spraying.
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Ensure that the hose material is chemically resistant to the sprayed products.
Ensure that the material 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-trafc areas,
– on sharp edges,
– on moving parts, or
– on hot surfaces
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the complete high-pressure hose must be less than 1 Mohm.
4.2.3 MATERIAL HOSES
4.2.4 CLEANING
De-energize the device electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the device.
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.
To clean, use cloths and brushes moistened with solvent. Abrasive agents or objects
must not be used. Ensure that the spray gun is not damaged in any way while cleaning.
Parts of the spray gun must not be sprayed with or immersed in cleaning agent.
Preferably, non-combustible cleaning agents should be used.
The choice of the appropriate cleaning agent for cleaning purposes of 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.
Ensure that no electrical component is cleaned with nor even immersed into solvent.
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.
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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 wear safety goggles, protective
clothing and gloves, as well as hand 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.
4.3 CORRECT USE
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.
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.
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4.4 SAFETY INFORMATION ON DISCHARGES
The plastic parts of the spray gun are charged electrostatically by the high-voltage eld of
the spray gun. In case of c ontact with plastic parts harmless discharges (brush discharges)
may occur. They are completely non-hazardous for human health.
When keeping a distance of 4 to 10 mm; 0.15 to 0.4 inch between spray gun and object to
be sprayed, the corona discharge at the end of the electrode is visible in the dark.
Surface spraying of the control unit
Never spray device parts using electrostatic equipment (electrostatic spray gun!).
Cleaning the control unit
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.
4.5 PROTECTIVE AND MONITORING EQUIPMENT
Protective and monitoring equipment!
Risk of injury and equipment damage.
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.
WARNING
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5 DESCRIPTION
5.1 AREAS OF APPLICATION
Incorrect use!
Risk of injury and equipment damage.
Only connect original Wagner spray guns or the Wagner
high-voltage Universal cascade to the VM 5000 control unit.
Only connect the GM 5000EA or GM 5000EAC spray guns.
WARNING
The VM 5000 control unit, together with the matching GM 5000EA or GM 5000EAC spray
gun and other components, form an electrostatic hand spray system. The VM 5000 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 limiting are adjusted on the control unit
and can be saved in three di erent recipes. The high-voltage supply is switched on and o
with 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 to earth) 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 FUNCTIONAL DESCRIPTION
Input voltage 115 VAC – 240 VAC, 50 Hz / 60 Hz
Input power max. 40 W
Input current max. 0.5 A
Output voltage max. 20 Vpp
Output current max. 1.0 A AC
High-voltage limiting 70 kV DC
Spray current limiting 100 μA DC
Polarity for negative high-voltage generators
Protection class IP 54 *
Weight (without cables) 2.3 kg; 5.07 lbs.
Operating temperature range 0 – 40 °C; 32 – 104 °F
5.3 TECHNICAL DATA
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VM 5000
A
B
C
B_03270
EXT
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R1
R2
VM 5000
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344501
Dimensions:
VM 5000
mm inch
A 250 9.84
B 180 7.09
C 120 4.72
Quantity Order No. Designation
1 2344480 VM 5000 control unit
The standard equipment includes:
Quantity Order No. Designation
1 264626 Mains cable USA; 2 m; 6.56 ft
1 130215 Grounding cable, 10 m, 32.8 ft
2 9951117 Delay-action fuse 1.0 AT
1 2316160 FM Control Document GM 5000E
1 2344501 VM 5000 operating manual, English
1 see 1.1 Operating manual in local language
The delivery note shows the exact scope of delivery.
5.4 SCOPE OF DELIVERY
* Splash water protection is only guaranteed when the gun cable socket is screwed to
the device plug and the mains cable plug is xed to the control unit plug with the
safety clip.