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Summary of Contents for Carlisle MS Series
- Page 1 SERVICE MANUAL MS Topcoat M4 Manual Powder Spray Gun 0518 II 2D 2mJ Model: 835069 IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all instructions in this manual. Keep this Service Manual for future reference. PA-17-07-R1 (08/2018) 1 / 39 www.carlisleft.com...
- Page 2 MANUAL CHANGES NOTE: This manual has been changed from revision PA-17-07-R0 to revision PA-17-07-R1. Reasons for this change are noted under “Manual Change Summary” inside the back cover of this manual. PA-17-07-R1 (08/2018) 2 / 39 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/FM: 10-16 European ATEX Directive ............................10 European ATEX Labels .............................11 Intended Use ................................12 Notice On Harmless Discharges ..........................13 Safety Considerations ............................... 14 Notes of Safety Hazard ............................. 14 Rules and Regulations .............................. -
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 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/Fm
ATEX EUROPEAN ATEX DIRECTIVE 2014/34/EU, ANNEX II The following instructions apply to equipment covered by Aggressive substances: e.g. acidic liquids or gases certificate number PTB 16ATEX5003: that may attack metals, or solvents that may affect polymeric materials. The equipment may be used with flammable gases and vapors with apparatus groups II and with temperature Suitable precautions: e.g. -
Page 11: European Atex Labels
ATEX MS Powder M4 Topcoat 835069 ATEX Product Marking Definitions 0518 II 2D EEx 2mJ Ex Certificate Number: PTB 16 ATEX 5003 PTB 16 ATEX 5003 Ser. No: XXXX PTB = Notified Body performing EC-type Type: M4 Topcoat Voltage max 100kV examination Current: 0.9A 16 = Year of examination... -
Page 12: Intended Use
ATEX INTENDED USE Safety Regulations for Electrostatic Powder Coating 1. The MS Topcoat M4 Manual powder gun is exclusively for WA R N I N G use in powder coating. It has been developed according to recognized safety regulations for use in potentially †... -
Page 13: Notice On Harmless Discharges
ATEX 12. The grounding of all conductive parts (hooks, chain conveyors, etc.) must be checked at least weekly. The Resistance to earth must be less than 1 MΩ (Mega Ohm). 13. When cleaning the powder gun and when replacing the nozzles, the controller must be switched off. 14. -
Page 14: Safety Considerations
ATEX When the high voltage is switched on, a glow or corona hazardous materials, threats to people and the discharge occurs at the tip. This is only visible in a dark environment and the necessary protective measures environment. When the electrode is near the grounded work and rules of conduct to be followed. - Page 15 ATEX Static charge Some possible consequences of static charge are charging of persons, electric shock or sparks. Charging of objects and persons must be avoided. Grounding All electrically conductive parts in the work area (1.5m sideways and 2.5 meters in depth by each booth operating according to DIN VDE 0745 part 10.2) and the work pieces must be grounded.
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Page 16: Rules And Regulations
ATEX Professional Association rules and regulations, Germany BGV A1 General provisions BGV A3 Electrical systems and equipment DGUV 209-052 Electrostatic coating TRBS 727 Guidelines for avoiding ignition hazards due Electrostatic charge VDMA 24371 Guidelines for the electrostatic coating with plastic powder •... -
Page 17: Introduction
INTRODUCTION INTRODUCTION PRODUCT DESCRIPTION SCOPE OF DELIVERY Application Article # Description The MS Topcoat M4 manual powder gun is designed 835069 Topcoat M4 exclusively for electrostatic coating with organic powders. 615040 (Included) Spray nozzle set Any other use is considered improper. The manufacturer PA-17-07-R0 Manual with spare and wear parts list is not liable for any resulting damage, the risk lies with the user alone! -
Page 18: Specifications
INTRODUCTION SPECIFICATIONS Dimension: Weight: 388 g (Without leads) Length: 350 mm (Flat spray nozzle) Electrical Data: Frequency: 40 kHz Output voltage: 100 kV DC Maximum Output current: Regulated by 0 – 90 µA Polarity: Negative Building class: 2mJ acc. EN 50050-2 Pneumatic Data: Input air pressure (Sprayed air): 6 bar... -
Page 19: Parts Breakdown
INTRODUCTION MS TOPCOAT M4 MANUAL PARTS BREAKDOWN Item # Description Body of the gun Operator panel Nozzle nut Flat spray nozzle Trigger Connector cable Controller Connection powder hose PA-17-07-R1 (08/2018) 19 / 39 www.carlisleft.com... -
Page 20: Wiring Diagram
INTRODUCTION WIRING DIAGRAM FUNCTION Upon actuation of the trigger (1) (controller is turned on), Since these particles have the same charge as the spray gun, they are repelled, distributed in a fine cloud and de- the (2) is activated in the spray gun. Simultaneously, the posited evenly on the grounded work piece. -
Page 21: Function Nozzle
INTRODUCTION FUNCTION NOZZLE The nozzles of MS Powder allows air to flow through freely. Flat fan nozzle The gun air is used to cool the electrode in the flat spray nozzle Gun Air High Voltage Round spray nozzle The gun air is used to cool the electrode and to ventilate the round spray nozzle. -
Page 22: Commissioning And Operation Of Ms Topcoat M4 Manual Powder Gun
INTRODUCTION COMMISSIONING AND SAFE HANDLING OF THE OPERATION OF MS TOPCOAT MANUAL POWDER GUN M4 MANUAL POWDER GUN 1. Never point powder spray at any person. NOTE 2. Persons with pacemakers may not at any time stand in the † Before you begin the installation and area between the spray gun and the coated work piece. -
Page 23: Installation
INSTALLATION INSTALLATION CONNECTING From Notice Connect Connect Controller Connect ground Controller Signal ground Safety rules (Yellow/Green) System ground Main cable Line Power Main Controller Safety rules Power Cable Main air Main Air Main air Controller 6 bar Oil and water free Connecting to Controller Manual powder gun cable Gun Connect... -
Page 24: Wiring Diagram Of Ms Topcase Control Module (Basic Model)
INSTALLATION WIRING DIAGRAM OF MS TOPCASE CONTROL MODULE (BASIC MODEL) Vibrator Control Signals 24VDC 230/110V 6 bar Inlet 50/60Hz Air Pressure PA-17-07-R1 (08/2018) 24 / 39 www.carlisleft.com... -
Page 25: Wiring Diagram Of Ms Topcase Control Module (Deluxe Model)
INSTALLATION WIRING DIAGRAM OF MS TOPCASE CONTROL MODULE (DELUXE MODEL) Vibrator Control Signals 24VDC 230/110V 6 bar Inlet 50/60Hz Air Pressure PA-17-07-R1 (08/2018) 25 / 39 www.carlisleft.com... -
Page 26: Connecting Manual Powder Gun
INSTALLATION CONNECTING MANUAL CONNECTABLE CONTROLLERS POWDER GUN MS TOPCOAT MANUAL POWDER GUN The powder hose we connect via a quick coupling. This enables a rapid plugging and unplugging powder hose by The MS Topcoat manual powder spray gun may only be a spring. -
Page 27: Operation
OPERATION OPERATION Requirements for good grounding are: • Any hangers used to suspend work pieces must be electrically conductive and connected to earth ground. The ground of these hangers should be checked at OPERATION least weekly. If the resistance regularly tests above 1 MOhm, the hangers should be cleaned more fre- quently than one week. -
Page 28: Changing Program On The Manual Powder Gun
OPERATION CHANGING PROGRAM ON THE MANUAL POWDER GUN Press the arrow key to go to the Program mode The LED P lights up red when the mode is activated. The program can be changed with the +/- button At the controller module, the selected program lights up. -
Page 29: Maintenance
MAINTENANCE MAINTENANCE MAINTENANCE MS TOPCOAT NOZZLE CHANGE M4 MANUAL POWDER GUN Removing the nozzle CAUTION † Maintenance, repair or replacement of parts may only be performed by trained personnel of MS Powder. WA R N I N G † Wear parts in the powder gun, marked with a W in the spare parts list, must be checked regularly and replaced if necessary. - Page 30 MAINTENANCE 4. Carefully pull out the nozzle tube (3) without twisting the gun body (4). 5. Clean the removed nozzle and powder gun with compressed air. 2. Screw the nozzle nut over the nozzle tube. 1. Clean the powder gun as described in paragraph interruption of work.
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Page 31: Troubleshooting Guide
MAINTENANCE TROUBLESHOOTING GUIDE General Problem Possible Cause Solution No electrostatics Replace fuse Defective fuse on the controller and no powder output No electrostatic Contact MS Service Error at the high-voltage generation (e.g. no wrap around or no Defective Cascade in spray gun Contact MS Service powder adhesion) Contact MS Service... -
Page 32: Parts Identification
PARTS IDENTIFICATION PARTS IDENTIFICATION 460430 460440 615260-01 460425 460450 615219-01 460240 615024 615028 460230 460240 615256 615260-01 615040 615260-01 615028 615024 460240 615256 615281 615083 460240 615256 615260-01 615024 MS TOPCOAT M4 MANUAL GUN SPARE PARTS Item # Description Wear Part 615256 Electrode Assembly 615219-01... -
Page 33: Accessories
PARTS IDENTIFICATION ACCESSORIES 615028 615040 (Standard) 615281 615083 FLAT SPRAY NOZZLE Part # Description 615040 Assembly, Flat Spray Nozzle & Electrode 615028 Assembly, Flat Spray Nozzle (Included in 615040) 615281 Assembly, Flat Jet Nozzle & Electrode 615083 Assembly, Flat Jet Nozzle G4 (Included in 615281) 460440 460430 460425... - Page 34 PARTS IDENTIFICATION 835075 MS Topcoat M4 with Hardwired Cable PA-17-07-R1 (08/2018) 34 / 39 www.carlisleft.com...
- Page 35 PARTS IDENTIFICATION POWDER HOSE Part # Description 810195-06 Powder Hose 6m, (10mm ID) 810195-08 Powder Hose 8m, (10mm ID) 810195-10 Powder Hose 10m, (10mm ID) 810190-16 Powder Hose 16m, (11mm ID) 810190-20 Powder Hose 20m, (11mm ID) GUN AIR HOSE Part # Description 421370-06...
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Page 36: Declaration Of Conformity
• IP64 85°C • EN 50050-2 • EN 50050-2, EN 50177 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 37 PARTS IDENTIFICATION PTB EU TYPE EXAMINATION CERTIFICATE PA-17-07-R1 (08/2018) 37 / 39 www.carlisleft.com...
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Page 38: Ptb Ec Type Examination Certificate
MANUAL CHANGE SUMMARY MANUAL CHANGE SUMMARY PA-17-07-R1 - Replaces PA-17-07-R0 with the following changes: Change Description Page(s) Change CE number Cover Update “SAFETY” section Update ATEX text Correct CE number in label and add text to last paragraph Update text in the table Add EN-16987 to bullet number 10 Change text in lines 3, 4, and 16 Change both Output Voltage, Output Current, Building Class, and Ignition protection in “SPECIFICATIONS”... - Page 39 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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