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SERVICE MANUAL
EN
Model: 805600 (Single), 805650 (Dual)
IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
PA-18-02-R0 (08/2018)
MS Topcoater Speedy
Powder Spray System
1 / 52
www.carlisleft.com
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Table of Contents
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Summary of Contents for MS Topcoater
- Page 1 SERVICE MANUAL MS Topcoater Speedy Powder Spray System Model: 805600 (Single), 805650 (Dual) IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all instructions in this manual. Keep this Service Manual for future reference. PA-18-02-R0 (08/2018) 1 / 52...
- Page 2 Carlisle Fluid Technologies MS Powder in any way, transmitted, transcribed, stored in an electronic system, or translated. MS Topcoat M4 manual powder gun, MS Topcoat A4 automatic powder gun, MS topcase S4 controller are trademarks of Carlisle MS Powder. All other product names are trademarks or registered trademarks of their respective owners.
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Page 3: Table Of Contents
MS Topcoat M4 Manual Parts Breakdown ....................... 42 Function ..................................43 Function Nozzle ................................ 44 Commissioning and Operation of MS Topcoat M4 Manual Powder Gun ..............45 Safe Handling of the Manual Powder Gun ....................... 45 (Continued On Next Page) - Page 4 PARTS IDENTIFICATION (Cont.): 32-50 Connecting ................................46 Connecting Manual Powder Gun ..........................47 Connectable Controllers MS Topcoat Manual Powder Gun ..................47 Operation .................................. 47 Maintenance MS Topcoat M4 Manual Powder Gun ....................48 Nozzle Change ................................. 48 Troubleshooting Guide ............................. 50 DECLARATION OF CONFORMITY: Decloration of Conformity ............................
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Page 5: Safety
If you do not have the manuals and safety literature for your MS Powder system, contact your local MS Powder representative or MS Powder. PA-18-02-R0 (08/2018) 5 / 52... -
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 hazard. - 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: Introduction
INTRODUCTION INTRODUCTION PRODUCT DESCRIPTION The MS topcoater is a small stand-alone coating unit. The It is put into operation quickly through a simple structure trolley consists of a topcoat M4 manual powder spray gun, and is well suited for smaller coating installations. Through a topcase S4 controller and a suction system. -
Page 11: Parts Breakdown
MS Topcase Control Unit S4 835069 MS Topcoat M4 manual gun 835015 Trolley Topcoater Single 835019 Trolley, Topcoater, Dual (Not Shown) Four Power Cables are available (Included with Topcase): 460147 Power Cable topcase EU (Included in 615300-01) 460148 Power Cord CH... -
Page 12: Building And Installation Topcoater
INTRODUCTION BUILDING AND INSTALLATION TOPCOATER TOPCOATER - PARTS LIST Item # Description Item # Description Manual Gun Rubber Bummper Injector Hose Bracket Control Module Vibrator Motor Suction System Extension Holder Holder Topcoat M4 Cleaning Unit Solid Tire PA-18-02-R0 (08/2018) 12 / 52... -
Page 13: Wiring Diagram Of Ms Topcase Control Module (Basic Model)
INTRODUCTION WIRING DIAGRAM OF MS TOPCASE CONTROL MODULE (BASIC MODEL) Vibrator Control Signals 24VDC 230/110V 6 bar Inlet 50/60Hz Air Pressure PA-18-02-R0 (08/2018) 13 / 52 www.carlisleft.com... - Page 14 6. After reading the manual, switch on the Topcase Implementing controller. For commissioning the Topcoater it needs a 230V outlet, a good conductive ground connection and an air connection with 6 bars. 1. Check all powder hose and electrical cable connections.
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Page 15: Spare Parts List- Topcoater
Spare Parts Trolley Box TROLLEY BOX - PARTS LIST Item # Part # Description Quantity 620210 Trolley Topcoater Elite Box 620240 Vibration Motor Topcoater 230 V 443930 Solid Tire D200mm 806000 MS Suction System Elite 615300 MS Topcase Basic Unit 835069 MS Topcoat M4... -
Page 16: Applicator Powder Hose Set - Parts List
INTRODUCTION APPLICATOR POWDER HOSE SET POWDER HOSE SET TOPCOATER (610138-XX) - PARTS LIST Item # Part # Description Wear Part 810195-XX Powder Hose 10/15.5 Antistatic (/m) 461742-XX Hand Gun Cable, Topcoat M4 421370-XX Gun Air Hose 620120 Velcro Bands Available Gun Cable and Powder/Air Hose lengths and ordering information is available in manuals for the respective applicators (PA-17-06 and PA-17-07). -
Page 17: Air Hose - Set Topcoater - Parts List
INTRODUCTION AIR HOSE - SET TOPCOATER AIR HOSE - SET TOPCOATER (610144) - PARTS LIST Item # Part # Description Wear Part 615235 Antikink Hose Ass’y 615236 Antikink Hose Ass’y All Hoses lengths are (/m). When ordered as a complete assembly 610144, the hoses will be shrink wrapped together. -
Page 18: Description Individual Parts
WA R N I N G † Connecting and operating the Elite Injector and the safety are to be observed in the operating instruc- tions for the corresponding MS ECUs described. The pictured 450.0 g relate setting to the coating with 400.0 g... -
Page 19: Maintenance
MAINTENAMCE MAINTENANCE MS Elite Injector (610015) MS ELITE INJECTOR (610015) - PARTS LIST Item # Description Quantity Wear Part Part # Main Body Intake System Elite 426636 Internal Tooth Locking Washer M9x14 421430 Set Screw M6x1 413162 Dosing Nozzle with O-Ring 620257 Powder Plug 426638 Lock Nut Intake 426639 Q.D. -
Page 20: Cleaning Intake System (620101) - Parts List
MAINTENAMCE Cleaning Intake System - 620101 CLEANING INTAKE SYSTEM (620101) - PARTS LIST Item # Description Part # Housing, Top 426655 Housing, Bottom 426656 Push to Connect Elbow Plug-In 10mm to 8mm 415742 Piston 426657 O-Ring, 19.5 x 3.0, FKM 411342 O-Ring, 20.35 x 1.78mm 445140 Push to Connect Fitting Male Elbow 10mm Tube Male 1/8” BPST 423450 Spring 450198... -
Page 21: Suction Pipe Components - Parts List
MAINTENAMCE SUCTION PIPE WITHOUT ELITE INJECTOR SUCTION PIPE COMPONENTS - PARTS LIST Item # Description Quantity Wear Part Part # O-Ring 417220 Inner Injector Pipe with O-Ring (1) 615127 O-Ring 417188 Outer Tube with O-Ring (3) 615128 Suction Intake with O-Ring (6) 615126 O-Ring 417186... -
Page 22: Product Description Ms Topcase Control Unit S4
Description Function 615300 MS Topcase Control Module (Basic) The MS topcase Control Unit S4 can be operated with either MS Corona or MS Tribo powder spray gun. The control 615305 MS Topcase control module (Deluxe) unit automatically detects which type of gun is attached. -
Page 23: Specifications
MAINTENAMCE 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. 1.4 A External frequency to gun: 40 kHz. -
Page 24: Overview Front Corona Mode
MAINTENAMCE OVERVIEW FRONT CORONA MODE GUN PANEL topcoat PRG: 1 12/10/2015 13:11:53 STANDARD PROGRAMS CLEANING – – 1.20 0.80 8 10 ONE LAYER TWO LAYER µA OFF ON – – 0.50 PNEUMATIC SETTINGS – – 0.80 1.20 Setting the Feed Air 0.10 The feed air is used to adjust the amount of powder. -
Page 25: Electrical Settings
MAINTENAMCE ELECTRICAL SETTINGS NOTE † In case of excessive amount of electricity 40 50 produced orange peel. ASSIGNMENT OF KEYS – PROGRAMS Bottom menu programs Setting the High Voltage Switch to the Programs With this, the high voltage of the gun can be adjusted. Depending on the powder charging is set between 40 kV to 80 kV. -
Page 26: Overview Front Tribo Mode
MAINTENAMCE OVERVIEW FRONT TRIBO MODE GUN PANEL topcoat PRG: 1 12/10/2015 13:11:53 STANDARD PROGRAMS CLEANING – – 1.20 0.80 8 10 ONE LAYER TWO LAYER µA OFF ON – – 0.50 PNEUMATIC SETTINGS – – 0.80 1.20 Setting the Dosage Air Setting the Feed Air The dosage air is used for setting the kinetic propulsion The feed air is used to adjust the amount of powder. -
Page 27: Assignment Of Keys
MAINTENAMCE ASSIGNMENT OF KEYS PROGRAMS Bottom Menu Programs – Switch to the Programs 0.50 CLEANING Setting the Gun Air With the gun air the charging can be controlled. The more Bottom Cleaning air the more gun powder charge. Settings 0.5 - 2 bar. Start cleaning up for press again 8 10 ONE LAYER... -
Page 28: Overview Front Corona Modus In Nm3
MAINTENAMCE GUN PANEL topcoat PRG: 1 12/10/2015 13:11:53 STANDARD 40 50 PROGRAMS CLEANING – – 40 50 40 50 ONE LAYER TWO LAYER µA OFF ON – – Setting the Dosage Air OVERVIEW FRONT CORONA The dosage air is used for setting the kinetic propulsion of MODUS IN Nm3 the powder cloud. -
Page 29: Electrical Settings
MAINTENAMCE ELECTRICAL SETTINGS NOTE † In case of excessive amount of electricity produced orange peel. 40 50 ASSIGNMENT OF KEYS PROGRAMS – Bottom menu programs Switch to the Programs Setting the high voltage With this, the high voltage of the gun can be adjusted. CLEANING Depending on the powder charging is set between 40 kV to 80 kV. Standard powder can be set with approximately 70 kV Metallic powders are set about 50 - 60 kV. -
Page 30: Connecting Hardware
MAINTENAMCE 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 31: Pin Assignment In/Output Connect
MAINTENAMCE PIN ASSIGNMENT IN/OUTPUT CONNECT IN- / OUTPUT CONNECT IN- / OUTPUT CONNECT 5 Extern Start Corona 6 Extern Start Tribo 4 Extern Start Wash Earth 3 24V DC 1 Vibrator 230V AC 2 Vibrator 0V AC LINE POWER LINE POWER 5 230V AC 6 0V AC Earth... -
Page 32: Installation
† Check that all components are provided for † Observe safety regulations mounting † The structure is the same for both, the MS Tribo and the MS Corona powder spray gun. The control module automatically detects which type of gun is attached. -
Page 33: Switch On The Topcase
INSTALLATION 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 34 INSTALLATION 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.
- Page 35 INSTALLATION 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.
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Page 36: Service On The Manual Powder Gun
INSTALLATION 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 37 INSTALLATION 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 38 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. Fluid Box The controller can be connected to a fluidized box by the Fluid Air port on the back panel.
- Page 39 INSTALLATION 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 †...
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Page 40: Product Description
DC charge to the electrode, creating an electrostatic field between the nozzle and the target. One of the many features of the MS Topcoat M4 manual powder gun is that the electrical energy, which is available from the resistive charging electrode, is limited to the optimum level of safety and efficiency. The system is... -
Page 41: Specifications
INSTALLATION SPECIFICATIONS Dimension: Weight: 388 g (Without leads) Length: 350 mm (Flat spray nozzle) Electrical Data: Frequency: 40 kHz Output voltage: 90 kV DC Maximum Output current: Regulated by 0 – 100 µA Polarity: Negative Building class: acc. EN 50050 Pneumatic Data: Input air pressure (Sprayed air): 6 bar Powder output quantity: Variable to 450 g/min... -
Page 42: Ms Topcoat M4 Manual Parts Breakdown
INSTALLATION 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-18-02-R0 (08/2018) 42 / 52 www.carlisleft.com... -
Page 43: Function
INSTALLATION FUNCTION Since these particles have the same charge as the spray Upon actuation of the trigger (1) (controller is turned on), the (2) is activated in the spray gun. Simultaneously, the gun, they are repelled, distributed in a fine cloud and de- powder (3) - as well as the air supply (4) is switched to the posited evenly on the grounded work piece. -
Page 44: Function Nozzle
INSTALLATION 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 45: Commissioning And Operation Of Ms Topcoat M4 Manual Powder Gun
INSTALLATION 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 46: Connecting
INSTALLATION CONNECTING Notice Connect From 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 47: Connecting Manual Powder Gun
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. operated with one of the following controllers: The electrical connection is permanently assembled. -
Page 48: Maintenance Ms Topcoat 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 49 INSTALLATION 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 50: Troubleshooting Guide
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 Contact MS Service Defective Cascade in spray gun powder adhesion) -
Page 51: Declaration Of Conformity
Product Description / Object of Declaration: Powder Applicators - M4 Topcoat Manual Applicator 835069 A4 Topcoat Automatic Applicator 835070 used with MS Topcase S4 Controller Models 615300 and 615305 This Product is designed for use with: Ignitable Coating Powders Suitable for use in hazardous area:... - Page 52 Carlisle Fluid Technologies is a global leader in innovative finishing technologies. Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice. DeVilbiss®, Ransburg®, MS®, BGK®, and Binks®, are registered trademarks of Carlisle Fluid Technologies, Inc. ©2018 Carlisle Fluid Technologies, Inc.
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