SERVICE MANUAL
EN
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.
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EN
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.
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EN
ABOUT THIS MANUAL
This manual is copyrighted. Unauthorized copying is prohibited by law. The manual
may not be reproduced in whole or in part without the prior written consent of
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.
In this manual, reference is made to different trademarks or registered trademarks.
Such references do not imply that the manufacturer in question approves this
manual in any way or is tied up in some way. We have endeavored to retain
the preferred spelling of the copyright owner in trademarks and trade names.
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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EN
CONTENTS
CONTENTS
SAFETY: 5-9
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 .............................................................................................................................................. 16
INTRODUCTION: 17-22
Product Description ................................................................................................................................................... 17
Specications ............................................................................................................................................................ 18
Parts Breakdown ....................................................................................................................................................... 19
Wiring Diagram .......................................................................................................................................................... 20
Function ..................................................................................................................................................................... 20
Function Nozzle ......................................................................................................................................................... 21
Commissioning and Operation of MS Topcoat M4 Manual Powder Gun .................................................................. 22
Safe Handling of the Manual Powder Gun ................................................................................................................ 22
INSTALLATION: 23-26
Connecting ................................................................................................................................................................ 23
Wiring Diagram of MS Topcase Control Module (Basic Model) ................................................................................. 24
Wiring Diagram of MS Topcase Control Module (Deluxe Model) .............................................................................. 25
Connecting Manual Powder Gun............................................................................................................................... 26
Connectable Controllers MS Topcoat Manual Powder Gun ...................................................................................... 26
OPERATION: 27-28
Operation ................................................................................................................................................................... 27
Grounding .................................................................................................................................................................. 27
Changing Program on the Manual Powder Gun........................................................................................................ 28
Changing Powder Quantity on the Manual Powder Gun ........................................................................................... 28
MAINTENANCE: 29-31
Maintenance MS Topcoat M4 Manual Powder Gun .................................................................................................. 29
Nozzle Change .......................................................................................................................................................... 29
Troubleshooting Guide .............................................................................................................................................. 31
PARTS IDENTIFICATION: 32-38
MS Topcoat M4 Manual Gun Spare Parts ................................................................................................................. 32
Accessories ............................................................................................................................................................... 33
Declaration of Conformity .......................................................................................................................................... 37
PTB EC Type Examination Certicate ....................................................................................................................... 38
MANUAL CHANGE SUMMARY: 39
Manual Changes ....................................................................................................................................................... 39
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EN
SAFETY
SAFETY PRECAUTIONS
SAFETY
Before operating, maintaining or servicing any
Technology MS Powder electrostatic coating system
and understand all of the technical and safety literature for
your MS Powder products. This manual contains information
that is important for you to know and understand. This
information relates to USER SAFETY and PREVENTING
EQUIPMENT PROBLEMS. To help you recognize this
information, we use the following symbols. Please pay
particular attention to these sections.
WARNING
!
A WARNING! states information to alert you to
a situation that might cause serious injury if
instructions are not followed.
CAUTION
!
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
Carlisle Fluid
, read
WARNING
!
The user MUST read and be familiar with
the Safety Section in this manual and the safety
literature therein identied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly
understood by ALL personnel who operate, clean
or maintain this equipment! Special care should be
taken to ensure that the WARNINGS and safety
requirements for operating and servicing the
equipment are followed. The user should be aware
of and adhere to ALL local building and re codes
and ordinances as well as NFPA-33 AND EN 50177
SAFETY STANDARDS, LATEST EDITION, or
applicable country safety standards, prior to installing,
operating, and/or servicing this equipment.
WARNING
!
NOTE
A NOTE is information relevant to the procedure
in progress.
While this manual lists standard specications and service
procedures, some minor deviations may be found between
this literature and your equipment. Differences in local codes
and plant requirements, material delivery requirements,
etc., make such variations inevitable. Compare this manual
with your system installation drawings and appropriate MS
Powder equipment manuals to reconcile such differences.
Careful study and continued use of this manual will provide a
better understanding of the equipment and process, resulting
in more efcient operation, longer trouble-free service and
faster, easier troubleshooting. If you do not have the manuals
and safety literature for your MS Powder system, contact
your local MS Powder representative or MS Powder.
The hazards shown on the following pages may
occur during the normal use of this equipment.
Repairs may only be performed by authorized personel.
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EN
SAFETY
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, ushing or maintenance.
Spray booth ventilation must be kept at the rates
required by NFPA-33, EN 50177, EN 50050-2
OSHA, country, and local codes. In addition,
ventilation must be maintained during cleaning
operations using ammable or combustible
solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between the
parts being coated and the applicator. A distance of
1 inch for every 10KV of output voltage is required
at all times.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only
as instructed.
Non-factory replacement parts or unauthorized
equipment modications may cause re or injury.
If used, the key switch bypass is intended for use
only during setup operations. Production should
never be done with safety interlocks disabled.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC,
OSHA, local, country, and European Health and
Safety Norms.
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EN
SAFETY
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Explosion Hazard
Improper or inadequate
operation and maintenance
procedures will cause a
re hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Electrostatic arcing must be prevented. Safe sparking
distance must be maintained between the parts being
coated and the applicator. A distance of 1 inch for
every 10KV of output voltage is required at all times.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class II, Division 1 or 2 hazardous, zone 21
or zone 22 areas.
Test only in areas free of ammable or combustible
materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding
section of the equipment manual. Protection against
inadvertent arcing that is capable of causing re
or explosion is lost if the current overload sensitivity
is not properly set. Frequent power supply
shutdown indicates a problem in the system which
requires correction.
General Use and
Maintenance
Improper operation or
maintenance may create
a hazard.
Personnel must be properly
trained in the use of this
equipment.
Always turn the control panel power off prior to
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no objects
are within the safe sparking distance.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance with
NFPA-33, EN 50177, EN 50050-2.
Have re extinguishing equipment readily available
and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, re protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
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EN
SAFETY
AREA
Tells where hazards
may occur.
Spray Area /
High Voltage
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re
or explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on
conveyors or hangers that are properly grounded.
The resistance between the part and earth ground
must not exceed 1 meg ohm. (Refer to NFPA-33,
EN 50177)
Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator
via conductive gloves or gloves with the palm section
cut out.
NOTE: REFER TO NFPA-33 EN 50177 OR
SPECIFIC COUNTRY SAFETY CODES
REGARDING PROPER OPERATOR
GROUNDING.
All electrically conductive objects in the spray area,
with the exception of those objects required by the
process to be at high voltage, must be grounded.
Grounded conductive ooring must be provided in
the spray area.
Always turn off the power supply prior to cleaning,
or working on powder system equipment.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class II, Division 1 or 2, zone 21 or zone
22 hazardous areas, in accordance with NFPA-33.
Do not touch the applicator electrode while it is
energized.
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EN
SAFETY
AREA
Tells where hazards
may occur.
Electrical
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a re or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shut-
down indicates a problem in
the system which requires
correction.
An electrical arc can ignite
coating materials and cause a
re or explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specically approved for use in hazardous
locations, the power supply, control cabinet, and all
other electrical equipment must be located outside
Class II, Division 1 and 2, zone 21 or zone 22
hazardous areas in accordance with NFPA-33 and
EN 50177, EN 50050-2,
Turn the power supply OFF before working on the
equipment.
Test only in areas free of ammable or combustible
material.
Testing may require high voltage to be on, but only
as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
Chemical HazardToxic Substances
Certain materials may be
harmful if inhaled, or if there is
contact with the skin.
Follow the requirements of the Safety Data Sheet
supplied by coating material manufacturer.
Adequate exhaust must be provided to keep the air
free of accumulations of toxic materials.
Use a mask or respirator whenever there is a chance
of inhaling sprayed materials. The mask must be
compatible with the material being sprayed and its
concentration. Equipment must be as prescribed
by an industrial hygienist or safety expert, and be
NIOSH approved.
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EN
ATEX
EUROPEAN ATEX DIRECTIVE 2014/34/EU, ANNEX II
The following instructions apply to equipment covered by
certicate number PTB 16ATEX5003:
1. The equipment may be used with ammable gases and
vapors with apparatus groups II and with temperature
class T6.
2.
The equipment is only certied for use in ambient
temperatures in the range 5°C to +40°C and should
not be used outside this range.
3.
Installation shall be carried out by suitably trained
personnel in accordance with the applicable code of
practice e.g. EN 60079-14:1997.
4. Inspection and maintenance of this equipment shall be
carried out by suitably trained personnel in accordance
with the applicable code of practice e.g. EN 60079-17,
EN 50050-1, EN 50177.
5. Putting into service, use, assembling, and adjustment
of the equipment shall be tted by suitably trained
personnel in accordance with the manufacturer's
documentation.
Aggressive substances: e.g. acidic liquids or gases
that may attack metals, or solvents that may affect
polymeric materials.
Suitable precautions: e.g. regular checks as part of
routine inspections or establishing from the material's
data sheets that it is resistant to specic chemicals.
Refer to "Specications" in the "Introduction" section:
The characteristics of the equipment shall be detailed
8.
e.g. electrical, pressure, and voltage parameters.
The manufacturer should note that, on being put into
service, the equipment must be accompanied by
a translation of the instructions in the language or
languages of the country in which the equipment is to
be used and by the instructions in the original language.
Refer to the "Table of Contents" of this service manual:
a. Installation
b. Operation
c. Maintenance
d. Parts Identication
6. Components to be incorporated into or used as
replacement parts of the equipment shall be tted
by suitably trained personnel in accordance with the
manufacturer's documentation.
7. The certication of this equipment relies upon the
following materials used in its construction:
If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility of
the user to take suitable precautions that prevent it
from being adversely affected, thus ensuring that the
type of protection provided by the equipment is not
compromised.
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EN
MS Powder M4 Topcoat 835069 ATEX
Product Marking Denitions
ATEX
Ex Certicate Number: PTB 16 ATEX 5003
PTB = Notied Body performing EC-type
examination
16 = Year of examination
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is
entitled Encapsulation)
003 = Document serial number
X = Special conditions for safe use apply
Product Marking
II 2 D
Ex = Specic marking of explosive protection
II = Equipment Group hazardous area
characteristics
2 = Equipment Category
D = Type of explosive atmosphere (dust)
0518 II 2D EEx 2mJ
PTB 16 ATEX 5003
Ser. No: XXXX
Type: M4 Topcoat Voltage max 100kV
Current: 0.9A
EEx 2mJ = The MS Powder M4 Topcoat applicator is suitable
for use in automatic spraying installations complying with
EN 50050-2: 2013 as it is a Type A class according to EN
50177 with a discharge energy limit of 2mJ.
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EN
ATEX
INTENDED USE
1. The MS Topcoat M4 Manual powder gun is exclusively for
use in powder coating. It has been developed according
to recognized safety regulations for use in potentially
explosive atmospheres according to directive RL 2014/34/
EU.
2. Any other use is considered improper. The manufacturer
is not liable for any resulting damage. The risk lies by the
user alone. If the MS Topcoat M4 Manual powder gun or
its operating conditions are altered, or materials differing
from the manufacturer’s specications are to be used,
the written consent of MS Powder must be obtained.
3. Intended use also includes compliance with the
manufacturer's operating, maintenance and service
instructions. The MS Topcoat M4 Manual powder gun
may be used, maintained and repaired only by persons
who are trained on the equipment and its dangers.
4. Commissioning (this means the starting of operation as
directed) is prohibited until it is determined that the MS
Topcoat A4 automatic powder gun is installed and wired
in accordance with the Machinery Directive (2006/42/EC).
Also to note is the EN 60204-1 (Safety of machinery).
5. Unauthorized modications to the MS Topcoat M4 Manual
powder gun exclude the manufacturer from any liability.
6. The relevant accident prevention regulations and other
generally recognized safety, occupational health and
structural regulations must be observed.
7. Any country-specic safety regulations must also be
considered and observed.
Safety Regulations for Electrostatic
Powder Coating
WARNING
!
This equipment can be dangerous if it is not
operated according to the information in this manual!
In addition, the country-specic safety regulations for
re protection must be observed.
WARNING
!
Persons with pacemakers should not remain in
the area of electrostatic powder spraying. Strong
high voltage and electromagnetic elds can arise in
these areas.
The legislator describes (ZH 1/443, section 6.1):
CAUTION
!
The operator must ensure that the manual pow-
der coating equipment and accessories are tested as
required, this should be done at least annually by an
expert on safe working condition.
1. All electrostatic conductive parts, which are located
within a distance of 5m from the powder spray gun
and the work pieces must be grounded.
2. The oor of the coating area must be electrostatically
conductive (normal cement is generally conductive).
(Measurement according to EN1081)
3. The operator must wear anti-static footwear, for
example, leather soles. (According to EN 344-1 shoes).
4. When using the manual powder gun, the operator’s
hand must make intimate contact with the handle.
Explosion
Protection
0518 II (2) D IP64 85°C IP64 T6 (Zone 22)
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Protection
Class
Max Surface
Temperature
If gloves are worn, they must be electrostatically
conductive, or the palm must have a suitable cut out
to allow direct contact with the black part of the handle.
An example of a suitable cut out is shown on the next
page. (EN 1149-1, EN 1149-2)
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