Carlisle MS Series, MS TOPCOAT M4 Service Manual

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.

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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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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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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

Specications ............................................................................................................................................................ 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 Certicate ....................................................................................................................... 38

MANUAL CHANGE SUMMARY: 39

Manual Changes ....................................................................................................................................................... 39

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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 identied.

 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 specications 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 efcient 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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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 modications 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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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.

Unless specically 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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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 specically 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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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 specically 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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ATEX

EUROPEAN ATEX DIRECTIVE 2014/34/EU, ANNEX II

The following instructions apply to equipment covered by

certicate number PTB 16ATEX5003:

1. The equipment may be used with ammable gases and

vapors with apparatus groups II and with temperature class T6.

The equipment is only certied for use in ambient

temperatures in the range 5°C to +40°C and should not be used outside this range.

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 specic chemicals.

Refer to "Specications" 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 Identication

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 certication 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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MS Powder M4 Topcoat 835069 ATEX

Product Marking Denitions

ATEX

Ex Certicate Number: PTB 16 ATEX 5003

PTB = Notied 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 = Specic 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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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 specications 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 modications 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-specic 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-specic 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)

Page 13

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. When working with cleaning agents that can develop hazardous fumes, the manufacturer’s instructions must be observed. Flammable cleaning agents should not

be used. Before using ammable cleaners, the powder

spraying device must be turned off, separated from the power supply, secured against reconnection and allowed to discharge to less than .24mJ.

5. The supplied grounding cable (green / yellow) must be connected to the grounding screw of the electrostatic automatic powder coating equipment. The grounding cable must have good metallic connection with the coating enclosure, the recovery unit and the conveyor

chain respectively. Any suspended objects must be

connected to the earth ground of the building.

6. The voltage and powder feed lines to the powder guns must be protected against mechanical, thermal and chemical damage.

7. The main power connection of the MS powder coating device must be electrically interlocked with the exhaust system of the powder coating enclosure. The powder coating device may only be switched on if the exhaust air is running.

8. The booth air must be interlocked with the controller of the powder applicator. If the booth is switched off the controller is off.

9. The powder spray gun may only be operated in a powder spray enclosure with industrial ventilation. Operation creates a hazard zone around the powder spray gun.

15. Powder must be used according to the manufacturer’s instructions.

16. When disposing of powder and cleaning agents, manufacturer’s instructions and the applicable environmental protection regulations must be observed.

17. In the case of damage (broken parts, cracks, etc), these components should be removed and the automatic powder gun no longer operated.

Repairs may not under any circumstances be carried

18. out in a hazardous area. Repairs must be performed by authorized service centers from MS Powder. Only original spare and wear parts from MS Powder may be used or warranty and agency approval are voided.

NOTICE ON HARMLESS DISCHARGES

10.

The operator must ensure that an average concentration of powder in the air does not exceed 50% of the lower explosive limit (UEG=maximum permissible powder/ air concentration). If the UEG is not reliably known, the mean UEG must not exceed 10g/m3 (must meet

requirements of EN 12981, EN-16987).

11. The powder spraying equipment should be checked annually by the operator for explosion protection.

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Page 14

ATEX

When the high voltage is switched on, a glow or corona discharge occurs at the tip. This is only visible in a dark environment. When the electrode is near the grounded work piece, this physical phenomenon can be observed. This glowing discharge does not cause any ignition and does not affect the functioning of the system. When the electrode approaches the work piece, the controller automatically reduces the high voltage to a safe value or, depending on the setting, switches the high voltage off.

Touching the plastic parts of the automatic powder gun

with your nger can cause harmless discharges called

brush discharges. These discharges on the plastic parts

are caused by the high voltage eld of the gun. However,

they have no ignition energy.

SAFETY CONSIDERATIONS

Any person who is responsible for the installation, commissioning, operation, maintenance and repair of powder spraying device must have read and understood the operating instructions and particularly the "Safety" section. The user company must ensure that the user has the necessary professional knowledge to deal with the powder spraying device and its hazards. The control units of the spray guns must be installed and operated in Zone 22. Spray guns are approved for Zone 21. The powder spraying device may only be operated by trained and authorized service personnel. This applies especially to work on the electrical equipment which may only be performed by appropriate specialists. Before doing any work concerning installation, commissioning, setup, operation, changes in operating conditions and modes of operation, maintenance, inspection or repair, the necessary shutdown

procedures specied in the operating instructions must be

performed. The powder spraying device is turned off by using the main switch or, if it exists, by emergency switch off. The individual components can be switched on and off during operation by use of the respective switches.

Individual safety instructions for the user company and / or operating personnel.

1. The user is to refrain from any work which compromises the technical safety of the powder spraying device.

hazardous materials, threats to people and the environment and the necessary protective measures and rules of conduct to be followed. These operating instructions must be written in the language of the workforce in an understandable form and placed in an appropriate location known to the workforce.

4. The operator is obliged to check the entire powder spraying system at least once per shift for apparent damages and to immediately report any changes (including in performance) affecting safety.

5. The company must ensure that the spray powder unit is only operated in perfect condition.

6. Where necessary, the company will provide the operator with protective clothing (e.g. face mask).

7. The user must ensure cleanliness and clarity of the workspace at and around the powder spraying device.

8. No safety equipment may be disconnected or removed from service. If the disconnection of safety devices is required for equipping, repairing or maintaining the equipment, the safety devices must be reassembled immediately after the completion of maintenance. All maintenance activities may only be carried out on a disconnected powder spraying device.

9. Activities such as controlling powder uidization, adjusting high voltage or similar may not be carried

out on an active spray device.

NOTES OF SAFETY HAZARD

Current/Voltage

It is important to reiterate there is an imminent danger to life through high voltage if shutdown procedures are not followed correctly.

Energized equipment must not be opened, and the power plug should not be pulled while energized, otherwise there is a risk of electric shock.

2. The operator must help to ensure that no unauthorized persons work on the powder spraying device (e.g. by installing devices to protect against unauthorized use).

3. The employer must create and operating instruction for the use of hazardous substances. These instructions must detail what must occur during handling of

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Powder

Unfavorable powder concentrations in air may ignite in the presence of sparks. It is the user’s responsibility to ensure

sufcient air in the coating enclosure. Powder lying on the oor around the powder spraying device constitutes an

imminent risk of slipping.

Page 15

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. The resistance to earth of each work piece must not exceed 1 Mohm. This resistance must be checked regularly. Any holders or hangers for the work piece must ensure the work pieces remain grounded. If the work piece is suspended, the hanger must be kept clean so that the necessary conductivity can be retained. To check the grounding, suitable instruments should be ready at the workplace.

Pneumatic

For longer work interruptions or downtime, the powder spraying device must be depressurized. Damage to the pneumatic hose with uncontrolled leakage and improper

use of compressed air may result in injury.

ATEX

Crushing and shearing points

During operation, moving parts may move move automatically in the workspace. Only trained and authorized persons may approach this equipment. Barriers must be carried out on site in accordance with local safety regulations.

Access restrictions for a specic reason

The user must ensure that local conditions are met when repairs are conducted on electrical parts. Additional measures, such as barriers, shall be taken to prevent unauthorized access.

Prohibition of unauthorized conversions and

modications to the machine

Any unauthorized modications or changes to the powder

spraying device are not permitted for safety reasons. The powder spraying device may not be used if damaged, and the defective part must be immediately replaced or repaired. Only original MS Powder spare parts may be used. Damage due to use of other parts invalidates the warranty. Repairs may only be carried out by a specialist or authorized repair

center. Unauthorized modications can lead to personal injury and property damage. The warranty provided by MS

Powder and the agency approvals are voided.

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Page 16

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

• Part 1 General requirements

• Part 2 Assembly examples

European Guidelines

RL2014/34/EU Approximation of the laws of the Member States concerning equipment and protective

systems intended for use in potentially explosive atmospheres

EN 12100 Safety of machinery

ATEX

EN 50050-2: 2013 Electrical equipment for potentially explosive atmospheres - Electrostatic manual

EN 50177

powder coating equipment

Stationary electrostatic spraying equipment for ammable coating powder

EN 12981 Coating plants spray booths for organic powder coating / safety requirements.

EN 60 529, identical: IP degrees of protection; Contact, foreign matter and water protection for electrical DIN 40050 equipment

EN 60 204 identical: VDE guidelines for the electrical equipment of manufacturing and processing machines with nominal voltages up to 1000V

2006/42/EG Machine guidelines

EN 60204-1 Safety of machinery-electrical equipment of machines

2004/108/EG EMC Electromagnetic Compatibility Directive

International-regulations

IEC 61000-4-1 Electromagnetic compatibility (EMC) Testing an measurement techniques IEC 61000-4-3 IEC 61000-6-2 IEC 61000-6-4

IEC 55011

*Sources

Carl Heymanns Verlag KG, Luxemburger Strasse 449, 5000 Köln 41 or competent for the member companies

Professional Association

Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30

VDE-Verlag GmbH, Bismarckstrasse 33, 1000 Berlin 12

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Page 17

INTRODUCTION

PRODUCT DESCRIPTION

Application

The MS Topcoat M4 manual powder gun is designed exclusively for electrostatic coating with organic powders. Any other use is considered improper. The manufacturer is not liable for any resulting damage, the risk lies with the user alone!

The MS Topcoat M4 manual powder gun is suitable for

electrostatic coating of objects of all shapes and geometries,

which can be grounded.

INTRODUCTION

SCOPE OF DELIVERY

Article #

835069 Topcoat M4

615040 (Included) Spray nozzle set

PA-17-07-R0 Manual with spare and wear parts list

The Topcoat M4 manual receives power from a controller which powers a cascade that generates a high voltage

DC charge to the electrode, creating an electrostatic eld

between the nozzle and the target.

Description

Foreseeable misuse

• Coating of ungrounded objects

• Use of enamel powder

• Incorrectly set values of the powder feed

• Incorrectly set values of the electrode rising air

• Using moist powder

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 efciency. The system is incapable of releasing sufcient electrical or thermal energy

during normal operating conditions to cause ignition of

specic hazardous materials in their most easily ignited

concentrations in air.

As the applicator electrode approaches ground, applicator circuitry causes the high voltage to approach zero while the current approaches its maximum value. This performance is validated by an independent test agency that gives ATEX

EN 50 050-2: 2013.

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Page 18

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

Powder output quantity: Variable to 450 g/min

INTRODUCTION

Compressed Air Quality According ISO 8573.1:

Residual water content in compressed air: max. 1.3 g/m3 with a dew point of 7 °C

Residual oil in the compressed air: max. 0.01 mg/m3

Air throughput: max. 5-20 m3/h

Ambient Condition: When using low temperature powders may be necessary

an ambient temperature of below 30 ° C.

Workable Powder: Plastic powder Metallic-powder

Permission: PTB16 ATEX 5003

Protection class: IP 64

Ignition protection: 2mJ acc. EN 50050-2

Temperature range: 0 °C … +85 °C (32 °F ... +185 °F)

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Page 19

INTRODUCTION

MS TOPCOAT M4 MANUAL PARTS BREAKDOWN

Item # Description

1 Body of the gun

2 Operator panel

3 Nozzle nut

4 Flat spray nozzle

5 Trigger

6 Connector cable Controller

7 Connection powder hose

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Page 20

WIRING DIAGRAM

INTRODUCTION

FUNCTION

Upon actuation of the trigger (1) (controller is turned on), the (2) is activated in the spray gun. Simultaneously, the

powder (3) - as well as the air supply (4) is switched to the

spray gun. The powder moves along the gun and comes into contact with the high voltage.

The high voltage differential between the grounded work piece and the electrode of the coating gun generates an

electric eld, which transmits a negative charge on the

individual powder particles.

Since these particles have the same charge as the spray

gun, they are repelled, distributed in a ne cloud and de-

posited evenly on the grounded work piece. Powder that does not initially make contact with the work piece is caught

in the electrical eld and wraps around to the backside of

the work piece. This powder coating technology provides more effective material utilization, time savings, greatly improved coating quality, minimal cleaning effort and a healthy working environment.

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Page 21

FUNCTION NOZZLE

The nozzles of MS Powder allows air to ow through freely.

Flat fan nozzle

The gun air is used to cool the electrode in the at

spray nozzle

Gun Air

INTRODUCTION

High Voltage

Round spray nozzle

The gun air is used to cool the electrode and to ventilate the round spray nozzle.

High Voltage

Gun Air

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Page 22

INTRODUCTION

COMMISSIONING AND OPERATION OF MS TOPCOAT M4 MANUAL POWDER GUN

NOTE

 Before you begin the installation and commissioning, take a moment to familiarize yourself with the relevant manuals.

 Check that all components for mounting are provided.

 A high quality of compressed air is necessary for operation of the powder coating system.

CAUTION

 When connecting the powder spray gun, the con- trol unit and the accessories, the controller must be switched off by using the main switch.

SAFE HANDLING OF THE MANUAL POWDER GUN

1. Never point powder spray at any person.

2. Persons with pacemakers may not at any time stand in the area between the spray gun and the coated work piece.

A high voltage eld is created here.

3. In case of error, solve the error as described in the section Maintenance: Troubleshooting.

4. Comply with local regulations for occupational safety and accident prevention regulations at all times.

5. Follow the information in this manual at all times, particularly the general safety instructions and warnings.

CAUTION

 You must be familiar with the operation of this

device before switching it on.

 DO NOT touch the gun nozzle when high voltage

is switched on.

 Do not stand in front of the spray gun.

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Page 23

INSTALLATION

CONNECTING

Connect

From

Notice

Connect Controller

Connect ground GND 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 Manual Controller Powder Gun

Powder gun air hose Gun air Manual Controller (Black) powder gun

Powder hose Powder Manual powder Powder hose

injector gun connector

Quick release

Connect Powder Injector

Feed air hose Feed Air (blue) Controller Powder injector

Dosage air hose Dosage Air (red) Controller Powder injector

WARNING

 The plug of the pistols cable is equipped with a nose, this has to be run in the groove of the sleeve. The plug is tightened with 0.6Nm torque.

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Page 24

INSTALLATION

WIRING DIAGRAM OF MS TOPCASE CONTROL MODULE

(BASIC MODEL)

6 bar Inlet

Air Pressure

Vibrator Control

Signals 24VDC

230/110V

50/60Hz

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Page 25

INSTALLATION

WIRING DIAGRAM OF MS TOPCASE CONTROL MODULE

(DELUXE MODEL)

6 bar Inlet

Air Pressure

Vibrator Control

Signals 24VDC

230/110V

50/60Hz

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Page 26

INSTALLATION

CONNECTING MANUAL POWDER GUN

The powder hose we connect via a quick coupling. This enables a rapid plugging and unplugging powder hose by a spring.

The electrical connection is permanently assembled.

WARNING

 Do not unplug the electrical plug. The power must be turned off at the control unit before unplugging the cable.

CONNECTABLE CONTROLLERS MS TOPCOAT MANUAL POWDER GUN

The MS Topcoat manual powder spray gun may only be operated with one of the following controllers:

• MS Topcase Basic (615300)

• MS Topcoat Deluxe (615305)

• MS Module (610189-10)

WARNING

 These devices may be used only for the applica-

tion described above.

Installation Instructions

Ensure there is a true earth ground connection available. Connect the powder source and air hose ground to this connection.

1 - Quick disconnect button 2 - Powder hose connection 3 - Gun air connection 4 - Controller cable electrical connector

2. Connect the air hose to the manual gun.

Connect the controller cable to the bottom of the gun and

the controller. Make sure the controller is switched off.

4. Using controller, turn on and actuate air without powder. Check for air leaks in the connectors.

5. Turn off the power to the powder gun using the controller.

6. Attach the powder hose to the back of the gun.

7. Turn on the powder gun using the controller and check for leaks in the powder connections.

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Page 27

OPERATION

On the back of the manual powder spray gun is a control panel. With this, the programs can be changed and the

amount of powder can be adjusted. By pressing the arrow

keys you can switch between program changes and powder quantity settings.

You can switch between the powder mode and the program mode

You can switch

Illuminates when the gun is ready for coating

between the powder mode and the program mode

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 least weekly. If the resistance regularly tests above 1 MOhm, the hangers should be cleaned more frequently than one week.

• The powder hose must have a resistance of less than 1 MOhm and should be regularly checked.

Important:

1. Powder residues must be regularly cleaned from hangers.

2. The grounding cable must be connected to the control unit.

WARNING

Increasing amount of powder / Program change

Reduce amount of powder / Program change

GROUNDING

Ground the powder coating system properly.

In order to achieve a good powder coating and for safety reasons (see safety regulations) must the powder coating system must be properly grounded.

Good grounding of the work piece is a prerequisite for optimum powder coating. A poorly grounded work piece causes:

 The grounding of all conductive parts (for exam- ple, hooks, chain conveyors, etc.) must be checked at least weekly.

 The Resistance to earth must be <1 MΩ (Mega Ohm).

WARNING

 All electrical supply lines must be equipped with grounding conductor and connected. Use only power cord with ground wire.

Earth grounding is on site Form with 16 mm tor to the system ground. The grounding cable must have a good metallic connection with the coating enclosure, the recovery unit and the conveyor chain. Any suspended ob-

jects must be connected to the earth ground of the building.

copper conduc-

1. Poor wrap-around

2. Uneven coating thickness

3. Back spray onto spray gun and user

4. Dangerous electric charging from the work piece

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Page 28

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

At the controller module, the selected

program lights up.

with the +/- button

CHANGING POWDER QUANTITY ON THE MANUAL POWDER GUN

Press the arrow key to go to the coating mode

The LED powder cloud lights up in green the mode is activated.

The amount of powder can be

Valves will be visible on the

controller module

WARNING

 For the operation of the installation follow the

operating instructions of the corresponding Control Units.

adjusted using the +/- button

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Page 29

MAINTENANCE

MAINTENANCE MS TOPCOAT M4 MANUAL POWDER GUN

CAUTION

 Maintenance, repair or replacement of parts may

only be performed by trained personnel of MS Powder.

WARNING

 Wear parts in the powder gun, marked with a W in the spare parts list, must be checked regularly and replaced if necessary.

Cleaning and changing nozzles Interruption of work

NOZZLE CHANGE

Removing the nozzle

1. Clean the powder gun as described above in Interruption of work

CAUTION

 For maintenance and cleaning work the controller

must always be switched off at the main switch.

If work is interrupted, the powder gun should be blown through and cleaned of residual powder.

Sequence advances:

1. Turn off controller.

2. Pull out the powder injector from injector connection,

so that no more powder can be conveyed.

. Hold the powder gun in the spray enclosure and clean

with compressed air the powder gun of powder.

2. Pull of nozzle (1) from the nozzle tube (3).

3. Unscrew the nozzle nut (2) from the gun body (4).

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Page 30

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.

MAINTENANCE

3 4

1. Clean the powder gun as described in paragraph interruption of work.

2. Remove the nozzle (1) from the nozzle tube.

3. Unscrew the nozzle nut (2) from the gun body (4).

4. Carefully pull out the nozzle tube (3) without twisting the gun body.

5. Clean the removed nozzle and powder gun with compressed air.

2. Screw the nozzle nut over the nozzle tube.

3. Insert the nozzle over the tube. Insert up to stop.

WARNING

 When removing and inserting the nozzle holder, always make sure the contact points are clean and undamaged.

Replacing the Nozzle

1. Insert the nozzle tube, making sure the area is clear and the contacts are lined up.

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 Do not clean the nozzles with solvent.

CAUTION

 Under all circumstances the manual powder guns must be dismounted for cleaning. (Connection cable etc.).

 There can be no guarantee for the safety of the user.

Page 31

TROUBLESHOOTING GUIDE

General Problem Possible Cause Solution

MAINTENANCE

No electrostatics and no powder output

No electrostatic (e.g. no wrap around or no powder adhesion)

Worse wrap around Back spray

Powder outlet

insufcient

Spray cloud no longer correct

Defective fuse on the controller

Error at the high-voltage generation

Defective Cascade in spray gun

Defect electric cable from gun to Controller

Incomplete grounding

No grounding

Compressed air main supply

insufcient

Feed air - dosage air ratio incorrect

Worn collector nozzle, propelling nozzle

in the injector

Worn nozzle system

Replace fuse

Contact MS Service

See chapter Grounding

Check the air supply

Feed air, dosage air check to Controller

Check, Replace

Replace nozzle system

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Page 32

PARTS IDENTIFICATION

460425

460430 460440

615028

615083

460450 615219-01

460230615028 460240

460240

615260-01

615256 615260-01

615040

615256

615281

615256 615024

615260-01

460240

615024

MS TOPCOAT M4 MANUAL GUN SPARE PARTS

Item #

615256 Electrode Assembly W

615219-01 Pressure Bar W

615260-01 Wire Assembly W

615028 Flat Spray Nozzle C3 MS Topcoat W

460420 Round Spray Nozzle D12 MS Topcoat W

460450 Round Spray Nozzle D24 MS Topcoat W

460440 Round Spray Nozzle D20 MS Topcoat W

460430 Round Spray Nozzle D16 MS Topcoat W

460230 Nozzle Nut MS Topcoat

615024 Nozzle Holder W

460240 Nozzle Tube

615083 Flat Jet Nozzle G4 MS Topcoat W

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Wear PartDescription

Page 33

PARTS IDENTIFICATION

ACCESSORIES

615040 (Standard)615028 615281 615083

FLAT SPRAY NOZZLE

Part #

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)

615254

Description

460450

ROUND SPRAY NOZZLES

Part #

615254 Round Spray Nozzle Set R1

460450 Round Spray Nozzle D24 (Included in 615254)

460440 Round Spray Nozzle D20 (Included in 615254)

460430 Round Spray Nozzle D16 (Included in 615254)

460425 Round Spray Nozzle D12 (Included in 615254)

Description

460440 460430

460425

HAND GUN CABLE, TOPCOAT, 9 PIN

Part #

461742-06 Hand Gun Cable 6m Topcoat

461742-08 Hand Gun Cable 8m Topcoat

461742-10 Hand Gun Cable 10m Topcoat

461742-16 Hand Gun Cable 16m Topcoat

461742-20 Hand Gun Cable 20m Topcoat

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Description

Page 34

PARTS IDENTIFICATION

835075 MS Topcoat M4 with Hardwired Cable

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Page 35

PARTS IDENTIFICATION

POWDER HOSE

Part #

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 #

421370-06 Tube, 6m, (4mm OD, 2.5mm ID)

421370-08 Tube, 8m, (4mm OD, 2.5mm ID)

421370-10 Tube, 10m, (4mm OD, 2.5mm ID)

421370-16 Tube, 16m, (4mm OD, 2.5mm ID)

421370-20 Tube, 20m, (4mm OD, 2.5mm ID)

Description

OPTIONALNOZZLE HOLDER

Part #

615129 Assembly, Nozzle Holder, High Wear

This nozzle holder can replace 615024 in applications with abrasive powder or high ow rates.

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Description

Page 36

PARTS IDENTIFICATION

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: Zone 21 Applicators, Controllers Zone 22

Protection Level: II 2D 2 mJ

Certicate: PTB 16ATEX 5003 Certicate: PTB 16ATEX 5004

Notied body details and role: PTB(0102)

EU Type examination and Issuing Certicate

Complies with the following provisions applying to it:

• 2006/42/EC (Machine Directive)

• 2004/108/EC (EMV Directive)

• 2002/95/EC (RoHs Directive)

• 2002/96/EC (WEEE Directive)

Applied standards: • EN 50050-2: 2013 • EN 61000-6-4: 2011

• EN 1127-1: 2011 • EN 62061: 2010

• EN 1953: 2010 • EN 6 10 10

• EN 60204-1: 2007 • EN 50177:2009/A1:2012

• EN ISO 80079-34: 2012

• EN 60529: 2000

• EN ISO 12100: 2011

• EN 61000-6-2: 2011

Applied national technical standards and specications, in particular:

• BGI 764

Identication: Topcase M4/A4

• 2016/34/EU (ATEX Directive)

• PTB 16 ATEX 5004 • PTB 16 ATEX 5003

• 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

0518 II (2) 3D

EU DECLARATION OF CONFORMITY

This Declaration of conformity / incorporation is issued under the sole responsibility of the manufacturer:

ATEX Directive 2014/34/EU by complying with the following statutory documents and harmonised standards:

EN 50050-2: 2013 Electrostatic hand-held spraying equipment. Safety requirements. Hand-Held spraying

equipment for ignitable coating powder

EN 50177: 2010 Stationary electrostatic application equipment for ignitable coating powders - Safety requirements

Providing all conditons of safe use / installation stated within the product manuals have been complied with and also installed in accordance with any applicable local codes of practice.

Signed for and on behalf of Carlisle Fluid Technoligies:

DJ Hasselschwert

16-Feb-18

Vice President: Global Product Development

IL-344

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Page 37

PTB EU TYPE EXAMINATION CERTIFICATE

PARTS IDENTIFICATION

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Page 38

MANUAL CHANGE SUMMARY

PA-17-07-R1 - Replaces PA-17-07-R0 with the following changes:

No.

1. Change CE number Cover

2. Update “SAFETY” section 5-9

3. Update ATEX text 10

4. Correct CE number in label and add text to last paragraph 11

5. Update text in the table 12

6. Add EN-16987 to bullet number 10 13

7. Change text in lines 3, 4, and 16 16

8. Change both Output Voltage, Output Current, Building Class, and Ignition protection in “SPECIFICATIONS” 18

9. Change the second item # to 615219-01 in line 2 and the drawing 32

10. Remove old page 35 and replace with “OPTIONAL NOZZLE HOLDER” table and expand other tables to ﬁll 36

11. Replace “DECLARATION OF CONFORMITY” with updated page 34

Change Description

Page(s)

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Page 39

WARRANTY POLICY

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 specic warranty information please contact Carlisle Fluid Technologies.

Carlisle Fluid Technologies is a global leader in innovative nishing technologies.

Carlisle Fluid Technologies reserves the right to modify equipment specications without prior notice.

DeVilbiss®, Ransburg®, MS®, BGK®, and Binks®,

are registered trademarks of Carlisle Fluid Technologies, Inc.

For technical assistance or to locate an authorized distributor, contact one of our international sales

and customer support locations.

Region

Americas

Europe, Africa

Middle East, India

China

Japan

Australia

Switzerland

Industrial / Automotive

Tel: 1-800-992-4657

Fax: 1-888-246-5732

Tel: +44 (0)1202 571 111

Fax: +44 (0)1202 573 488

Tel: +8621-3373 0108

Fax: +8621-3373 0308

Tel: +81 45 785 6421

Fax: +81 45 785 6517

Tel: +61 (0) 2 8525 7555

Fax: +61 (0) 2 8525 7575

Tel: +41 71 727 13 70

Email: sekretariat@carlisleft.eu

Automotive Renishing

Tel: 1-800-445-3988

Fax: 1-800-445-6643

For the latest information about our products, visit www.carlisleft.com.

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Carlisle MS Series, MS TOPCOAT M4 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual