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Summary of Contents for Carlisle MS Topcase 615300
- Page 1 SERVICE MANUAL MS Topcase Model: 615300 (Basic) 615305 (Deluxe) IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS, starting on page 5, and all instructions in this manual. Keep this Service Manual for future reference. PA-17-05-R1 (04/2018) 1 / 34 www.carlisleft.com...
- Page 2 MANUAL CHANGES NOTE: This manual has been changed from revision PA-17-05 to revision PA-17-05-R1. Reasons for this change are noted under “Manual Change Summary” inside the back cover of this manual. PA-17-05-R1 (04/2018) 2 / 34 www.carlisleft.com...
- Page 3 The information contained in this manual is complete and correct to the best of its knowledge and belief at the date of publication. The content is, however, no binding obligation for Carlisle MS Powder represents and the right to make changes without notice reserved.
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Page 4: Table Of Contents
CONTENTS CONTENTS SAFETY: Safety Precautions ..............................5 Hazards / Safeguards ..............................6 ATEX: European ATEX Directive ............................10 INTRODUCTION: 11-12 Product Description ..............................11 Scope of Delivery ..............................11 Specifications ................................12 USING “SOFT” CONTROLS: 13-17 Language Select ..............................13 Overview Front Corona Mode ..........................13 Pneumatic Settings .............................. -
Page 5: Safety
SAFETY SAFETY SAFETY PRECAUTIONS Before operating, maintaining or servicing any Carlisle Fluid WA R N I N G Technology MS Powder electrostatic coating system, read and understand all of the technical and safety literature for † The user MUST read and be familiar with the your MS Powder products. -
Page 6: Hazards / Safeguards
SAFETY AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Fire Hazard Spray Area Fire extinguishing equipment must be present in the Improper or inadequate spray area and tested periodically. operation and maintenance procedures will cause a fire Spray areas must be kept clean to prevent the... - Page 7 SAFETY AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Explosion Hazard Spray Area Improper or inadequate Electrostatic arcing must be prevented. Safe sparking operation and maintenance distance must be maintained between the parts being procedures will cause a coated and the applicator.
- Page 8 SAFETY AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Spray Area / Electrical Discharge High Voltage There is a high voltage device Parts being sprayed and operators in the spray Equipment that can induce an electrical area must be properly grounded.
- Page 9 SAFETY AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Electrical Discharge Electrical Unless specifically approved for use in hazardous Equipment locations, the power supply, control cabinet, and all High voltage equipment is utilized in the process.
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Page 10: Atex
ATEX EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6 The following instructions apply to equipment covered by Aggressive substances: e.g. acidic liquids or gases certificate number PTB 16ATEX5004: that may attack metals, or solvents that may affect polymeric materials. 1. The equipment may be used with flammable gases and vapors with apparatus groups II and with temperature Suitable precautions: e.g. -
Page 11: Introduction
INTRODUCTION INTRODUCTION PRODUCT DESCRIPTION Scope of Delivery Application The MS topcase control module is designed exclusively SCOPE OF DELIVERY for the control of MS powder applicators. Part # Description It controls and regulates the electrostatics and the air supply 615300 MS Topcase Control Module (Basic) to the powder spray guns and the vibrator. -
Page 12: Specifications
INTRODUCTION SPECIFICATIONS Dimension Weight: 4.4 kg Depth: 280 mm Width: 200 mm Height: 120 mm Electrical data Main: 100 - 240 VAC Frequency: 50 - 60 Hz Input power: 70 W (With vibrator 550W) External voltage to gun: max. 10 Veff External current to gun: max. -
Page 13: Using "Soft" Controls
USING “SOFT” CONTROLS USING “SOFT” CONTROLS LANGUAGE SELECT The higher feed air is set, the more powder output is achieved. (Settings between 0.6 - 3.5 bar) Changes language set. Setting The Dosage Air The dosage air is used for setting the kinetic propulsion of the powder cloud. -
Page 14: Electrical Settings
USING “SOFT” CONTROLS ELECTRICAL SETTINGS Setting The Current Control The current regulation has a great influence on the charge of the powder. As a rule, little electricity is used. Approximately Setting The High Voltage 20 µA. In weakly chargeable powder, the amount of current With this control, the high voltage of the gun can be adjusted. must be set higher. In case of applying a second or over Depending on the powder, charging is set between 40 kV coat or MDF coating, the amount of current can be set low: to 80 kV. -
Page 15: Overview Front Tribo Mode (Deluxe Unit)
OVERVIEW FRONT TRIBO If a lot of powder output is desired, the dosage air is set to be smaller. (0.2 - 0.6 bar) MODE (DELUXE UNIT) TOPCOAT PRG: 1 09/01/2018 13:43:45 STANDARD PROGRAMS CLEANING – – 0.00 0.00 40 50 40 50 ONE LAYER TWO LAYER... -
Page 16: Assignment Of Keys
USING “SOFT” CONTROLS Current Display ONE LAYER In Tribo mode this is not a setting but only a display of the microamp powder charge. If the current amount is set and this amount is achieved, an alarm will display. TWO LAYER 8 10 On Off Button OFF ON... -
Page 17: Cleaning
USING “SOFT” CONTROLS Cleaning NOTE In order to clean the gun and the powder hose, the CLEAN- ING button must be pressed. † Never have zero feed. CLEANING 40 50 The button will turn green and spray air briefly, then turn off again. There will be a delay until the button is pressed again. CLEANING –... -
Page 18: Installation
INSTALLATION INSTALLATION CAUTION † These units must be located outside the hazardous area (zone 22, class 1 division 2) CONNECTING HARDWARE From Notice Connect What Connector Name Control Module Connecting Connect ground cable GND (Yellow/Green) Controller True Earth Ground Safety regulations Main cable Line Power Main Supply... -
Page 19: Wiring Diagram Of Ms Topcase S4 Control Module
INSTALLATION WIRING DIAGRAM OF MS TOPCASE S4 CONTROL MODULE Vibrator Control Signals 24VDC 230/110V 6-8bar Inlet 50/60Hz Air Pressure PA-17-05-R1 (04/2018) 19 / 34 www.carlisleft.com... -
Page 20: Wiring Diagram Of Ms Topcase S4 Control Module Deluxe Unit
INSTALLATION WIRING DIAGRAM OF MS TOPCASE S4 CONTROL MODULE DELUXE UNIT Vibrator Control Signals 24VDC 230/110V 6 bar Inlet 50/60Hz Air Pressure PA-17-05-R1 (04/2018) 20 / 34 www.carlisleft.com... -
Page 21: Connecting - Installation Options Ms Topcase Control Module
INSTALLATION CONNECTING - INSTALLATION OPTIONS MS TOPCASE CONTROL MODULE Control module with MS Topcoat manual powder gun Control module with MS Topcoat automatic powder gun PA-17-05-R1 (04/2018) 21 / 34 www.carlisleft.com... -
Page 22: Four Control Module Set With Ms Topcoat Automatic Powder Gun
INSTALLATION FOUR CONTROL MODULE SET WITH MS TOPCOAT AUTOMATIC POWDER GUN PA-17-05-R1 (04/2018) 22 / 34 www.carlisleft.com... -
Page 23: Operation
OPERATION OPERATION COMMISSIONING AND CAUTION OPERATION OF MS TOPCOAT CONTROL MODULE † The mains connection of the MS powder coating device must be electrically interlocked with the exhaust system of the powder coater. The powder coating device must be switched on only when the CAUTION cabin is running. -
Page 24: Switch On The Topcase
OPERATION SWITCH ON THE TOPCASE Select Program After switching on, the desired program must be selected. For Main Switch this, press the button PROGRAMS. The program menu opens. Switch on the Topcase control module with the lever switch at the back. The touchscreen turns on. Switch ON The Powder Applicator The powder applicator turns on with the ON button. - Page 25 OPERATION When the topcase control unit is first delivered, three stan- 4. Select the desired number and give the program a dard programs are stored: name. By pressing on the field, a keyboard will be called 1 Standard in bar automatically. 2 Using Metallic Powder 9 Standard in Nm3 5. After changes are made and checked, the program can be stored pressing the SAVE PROGRAM button.
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Page 26: Operation
OPERATION Delete Program 4. Switch back to Program mode with the PROGRAM button. Programs can also be deleted at anytime. For this select the desired program (see “Select Program” section of this manual) and press the DELETE PROGRAM button. PROGRAMS DELETE PROGRAM 5. -
Page 27: Maintenance
MAINTENANCE MAINTENANCE SERVICE ON THE MANUAL POWDER GUN Program Change by the Manual Powder Gun Press the arrow key to go to the Program mode The “P” LED lights up red. The program mode is activated. GUN PANEL topcoat PRG: 1 12/10/2015 13:11:53 STANDARD PROGRAMS... - Page 28 MAINTENANCE Enter With the arrow buttons you can switch between pages. Standby Mode The powder applicator turns off with the OFF button. When the OFF button lights up red, work pieces cannot be coated. Main Switch Off Turn off the Topcase control module with the lever switch on the back.
- Page 29 MAINTENANCE Two Layer Mode In this mode one can adjust the settings used for the second coating. Two layer mode µA Area 2: Fluid Box And Cleaning Area 3: Standard Program In this area, the specified setting of the fluid box and clean- Here are the settings for the standard programs. These ing process can be set. are stored in the configuration menu, so that they cannot be overridden in the program mode. These are already set upon delivery of the MS topcase to the customer.
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Page 30: Grounding
MAINTENANCE Setting Gun Operation Mode Important: Sets the type of gun operation mode. 1. Powder residues must regularly be cleaned off of workpiece hangers 2. Connect the grounding cable to the control unit. Setting The Time And Date By pressing the field, a keyboard automatically pops up. CAUTION †... -
Page 31: Troubleshooting Guide
MAINTENANCE TROUBLESHOOTING GUIDE General Problem Possible Cause Solution Program error Program error Perform a reset. Device at the main switch ON / OFF on the back panel off, wait 20 Seconds, switch on again. No electrostatics, Faulty fuse on control board. Replace the fuse. -
Page 32: Declaration Of Conformity
II 2D 2mJ • PTB 16 ATEX 5004 • EN 50050-2: 2013 This Declaration of conformity / incorporation is issued under the sole responsibility of the manufacturer: Carlisle Fluid Technologies Inc. 16430 N Scottsdale Scottsdale, AZ 85254 EU DECLARATION OF CONFORMITY... -
Page 33: Manual Change Summary
MANUAL CHANGES MANUAL CHANGE SUMMARY PA-17-05-R1 - Replaces PA-17-05 with the folowing changes: Change Description Page(s) Insert “EUROPEAN ATEX DIRECTIVE” from PA-17-07 Add line of text to Permissions under SPECIFICATIONS Remove CP 2200 from image Replace this page with page 23 from PA-17-07 Insert new page for the Deluxe Unit with new backplate Replace the backplate in top Insert “Declaration of Conformity”... - Page 34 This product is covered by Carlisle Fluid Technologies materials and workmanship limited warranty. The use of any parts or accessories, from a source other than Carlisle Fluid Technologies, will void all warranties. For specific warranty information please contact Carlisle Fluid Technologies.
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