WAGNER VM 5000, Operating Manual

Page 1: ...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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Page 3: ...nt 14 4 1 2 Staff Qualifications 14 4 1 3 Safe Work Environment 14 4 2 Safety Instructions for Staff 15 4 2 1 Safe Handling of WAGNER Spray Devices 15 4 2 2 Grounding the Device 16 4 2 3 Product Hoses...

Page 4: ...g 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...

Page 5: ...s 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 dange...

Page 6: ...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 Langua...

Page 7: ...ry 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 rel...

Page 8: ...ombination with devices other than the above mentioned spray guns the SIRA authorization type approval ceases to be valid Theseelectrostaticmanualspraygunsaresuitableforsprayingliquidproducts inpartic...

Page 9: ...erved 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 desi...

Page 10: ...protective clothing Operation allergies observe safety data sheets maintenance disassembly Lacquer in air outside the defined working area Lacquering outside the defined working area Inhalation of sub...

Page 11: ...e 2 area VM 5000 control unit European Communities Notified body PTB Explosion proof equipment Device class II not mining Effective in zone Effective in zone 1 Ex atmosphere gas Number of type examina...

Page 12: ...e covers the control unit when used in conjunction with the spray gun The manufacturer certifies that the control unit can be used in zone 2 Cable connections Only the corresponding cables for the dev...

Page 13: ...12 18 13 14 15 22 16 17 21 19 20 B_04389 3 OPERATING MANUAL EDITION 08 2014 ORDER NUMBER DOC2318718 3 3 TYPE PLATE 1 Identification for category 3 zone 2 2 Identification for category 2 zone 1 3 Test...

Page 14: ...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 syst...

Page 15: ...tion can be suspended until the next start up 4 2 SAFETY INSTRUCTIONS FOR STAFF Alwaysfollowtheinformationinthismanual particularlythegeneralsafetyinstructions and the warning instructions Always foll...

Page 16: ...ury from recoil forces Ensure that you have rm footing when operating the spray gun Only hold the spray gun briefly in a position 4 2 2 GROUNDING THE DEVICE Friction flowing liquids and air or electro...

Page 17: ...hoses are never used to pull or move the device Suction hoses may not be subjected to pressure Several liquids have a high expansion coefficient In some cases their volume can rise with consequent dam...

Page 18: ...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 g...

Page 19: ...y 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 sp...

Page 20: ...mbination 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...

Page 21: ...x 0 5 A Output voltage max 20 Vpp Output current max 1 0 A AC High voltage limiting 80 kV DC Spray current limitation 100 A DC Polarity for negative high voltage generators Protection class IP 54 Weig...

Page 22: ...ay range 0 80 kV Single LED display Nominal voltage Bar display Working voltage 9 Illuminated display Spray current Lights up green Display range 0 100 A Single LED display Spray Current Limitation Ba...

Page 23: ...revolution Adjustment speed is proportional to rotational speed Used to adjust high voltage and spray current For setting parameter values in configuration mode 17 Push button Standby Mode 18 Illumin...

Page 24: ...ERATING MANUAL EDITION 08 2014 ORDER NUMBER DOC2318718 23 Mains input terminal Connection for mains cable with safety clip Warning Do not disconnect under voltage 24 Primary fuse 1 0 ampere slow actin...

Page 25: ...the device must be stored in a dry location free of vibrations and with a minimum amount of dust The device must be stored in enclosed rooms The air temperature at the storage location must be betwee...

Page 26: ...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 Gb B_03273 1 2 3 4 5 OPERATING MANUAL EDITION 08 2014 ORDER NUMBER D...

Page 27: ...y booth spray zone If possible set up the device outside the Ex zone Ex zone 2 is permissible Protect the device from significant temperature and moisture changes Protect the device from contamination...

Page 28: ...tion quality Ground all device components Ground the work pieces to be coated WARNING A poorly grounded work piece causes very bad wrap around uneven coating back spraying to the spray gun contaminati...

Page 29: ...of spray gun The spray gun is grounded via the spray gun cable The spray gun GM 5000EA or GM 5000EAC must be connected to the control unit VM 5000 via the spray gun cable Note for the sprayer Safety...

Page 30: ...y gun GM 5000EACF 2 Gun cable 3 Grounding cable 4 Pneumatic pump 5 Sliding table 6 Air pressure regulator air filter 7 Product suction system Pos Description 8 Return hose 9 High pressure filter 10 Co...

Page 31: ...ed in the relevant operating manuals Check that all product conveying connections are correctly connected Check that all air conveying connections are correctly connected Visually check the permissibl...

Page 32: ...clothing The footwear worn by operating staff must comply with EN ISO 20344 The measured insulation resistance must not exceed 100 megohms The protective clothing including gloves must comply with EN...

Page 33: ...High voltage field Danger to life from malfunction of heart pacemaker Make sure that persons with pacemakers Do not work with the electrostatic spray gun Do not enter the high voltage area DANGER In t...

Page 34: ...60 100 R3 40 80 Recipes 1 3 can be selected and saved directly with the program buttons R1 R2 and R3 Once the recipe required has been called up the individual coating parameters can be called up and...

Page 35: ...ltage bar graph display 8 is located above the High voltage button 21 If the control unit is in the ready position this light strip shows the set value as a dot Procedure 1 Press the High voltage butt...

Page 36: ...eshold is exceeded for example by the spray gun having approached the object being sprayed the high voltage is adjusted downwards until the threshold is no longer exceeded The set values for high volt...

Page 37: ...t and the value for high voltage is displayed in digits If you press the push button for current limitation the adjusted set value for the spray current limitation is displayed in digits Spraying usin...

Page 38: ...RDER NUMBER DOC2318718 7 5 STANDBY MODE If you want to spray without high voltage select the standby mode Press push button 17 briefly and the Standby illuminated display 18 lights up All the other LE...

Page 39: ...DOC2318718 7 6 DISPLAY PERFORM SERVICE Prerequisite The function Maintenance interval limit is activated Servicing the spray gun Once the time for the defined maintenance interval has expired the LED...

Page 40: ...g The set values for high voltage in kV and current limitation in A are set at the operating panel on The set values for high voltage in kV and current limitation in A are predefined using the interfa...

Page 41: ...utton off factory setting Lock is switched off 1 Partial lock of gun operating button Standby function disabled Recipe change is possible 2 Partial lock of gun operating button Recipe change disabled...

Page 42: ...42 VM 5000 OPERATING MANUAL EDITION 08 2014 ORDER NUMBER DOC2318718...

Page 43: ...7 The orange LED Standby 18 lights up 2 Press and hold the Service push button 14 3 Turn the universal control dial 16 with the other hand until the display 15 shows the number 10 Then release the Ser...

Page 44: ...r Service and theWagner production sites or theWagner Service Center which have the necessary infrastructure Group 1 illuminated display Parameters C11 to C20 for the end user Group 2 Parameters C21 t...

Page 45: ...MBER DOC2318718 The flashing LED display 13 indicates that the parameter value oFF in the display 15 can be changed with the universal control dial 16 Possible values in C11 are on or oFF Press and ho...

Page 46: ...nance hours counter When the control unit is in the ready position you can access the maintenance menu screen using the push button 14 Maintenance menu structure illuminated display 13 is activated Pu...

Page 47: ...the service interval limit in hours Procedure 1 Press the push button 3 briefly Illuminated display 6 lights up 2 Use the control dial 16 to set the maintenance interval limit you want e g 90 hours 3...

Page 48: ...respective parameters in the device configuration Control unit Interface cable External release Fault reset Fault output HV input A input HV output A output 24V DIN8 STN3PF06 LTV357 LTV357 GND GND GN...

Page 49: ...h voltage Analog DC current input between pin 4 in reference to pin 8 ground in 0 1V corresponds to 1kV 8 0V is the maximum specification and corresponds to 80kV 5 DC A in Set value specification for...

Page 50: ...intenance repair Danger to life and damage to the device 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...

Page 51: ...tric component is cleaned with or immersed into solvent DANGER Incompatibility of cleaning flushing agent and working medium Risk of explosion and danger of poisoning by toxic gases Examine the compat...

Page 52: ...sure that the device is checked for being in a reliable state after maintenance work is completed 8 2 1 MAINTENANCE STAFF 8 2 2 SAFETY INSTRUCTIONS Observe the safety instructions in Chapter 4 and Cha...

Page 53: ...completeness of the control unit must be checked regularly All sealed elements on the control unit must be present and undamaged During operation all electric connections of the control unit have to b...

Page 54: ...y No illuminated display lights up Mains supply not switched on Check and switch on mains supply Fuses defective Replace fuses Wagner Service No high voltage Spray gun cable not connected or defective...

Page 55: ...lace gun E21 E29 Exception error Hardware defect has occurred If problem persists contact the WAGNER Service Team E30 Cabinet door monitoring In Aquacoat operation switching on the high voltage with a...

Page 56: ...ve the safety instructions in Chapter 4 and Chapter 8 1 2 Before repair Flush and clean the system After repair work Check leak tightness of control unit as described in Chapter 10 3 Carry out a safet...

Page 57: ...with the household refuse but must be recycled in an environmentally correct manner WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it...

Page 58: ...le Europe 10 m 32 8 ft 241271 Mains cable Switzerland 3 m 9 8 ft 264626 Mains cable USA 2 m 6 6 ft 264625 Mains cable Japan 3 m 9 8 ft 2317600 Interface cable VM 5000 10 m 32 8 ft 130215 Grounding cab...

Page 59: ...ery air freight courier etc Identification in spare parts lists Explanation of column labeling in the following spare parts lists Wearing parts Note These parts are not covered by warranty terms Not p...

Page 60: ...las se Pr ote cti on Cl as s No rm St an da rd EN 50 05 0 IP 54 ma x 20 Vp p ma x 1 0 A Ei ng an gs str om Inp ut Cu rre nt ma x 0 5 A I 0 M ai n Sw it ch Nicht unter Spannung trennen Do not disconne...

Page 61: ...Print VM 5000 rear panel complete ET 13 3 263400 Distance bush 14 3 9922011 Serrated lock washer externally toothed 15 3 9910103 Hexagon nut 16 5 2312348 Hexagon lock nut 17 4 9922011 Serrated lock wa...

Page 62: ...than the address of the purchaser We do not provide warranty for damage that has been caused or contributed to for the following reasons Unsuitable or improper use faulty assembly or commissioning by...

Page 63: ...0050 2007 DIN EN 61000 6 2 2006 DIN EN ISO 12100 2011 DIN EN 1953 2010 DIN EN 61000 6 4 2011 DIN EN 60079 0 2010 DIN EN 60079 15 2011 DIN EN 60204 1 2007 Applied national technical standards and speci...

Page 64: ...ing with Liquid Ejection Devices Part 2 Chapter 2 29 Working with Coating Products Avoiding ignition risks Equipment for cleaning work pieces with solvents Guidelines for liquid ejection devices Paint...

Page 65: ...65 VM 5000 OPERATING MANUAL EDITION 08 2014 ORDER NUMBER DOC2318718...

Page 66: ...66 VM 5000 OPERATING MANUAL EDITION 08 2014 ORDER NUMBER DOC2318718...

Page 67: ...67 VM 5000 OPERATING MANUAL EDITION 08 2014 ORDER NUMBER DOC2318718...

Page 68: ...r No 2318718 Edition 08 2014 Germany Phone Fax E mail Switzerland Phone Fax More contact addresses on the internet at Company Locations WAGNER worldwide Subject to changes without notice Document No 1...