Carlisle MS Series User manual

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all

instructions in this manual. Keep this Service Manual for future reference.

Model: 835069

MS Topcoat M4 Manual

Powder Spray Gun

0518 II 2D 2mJ

PA-17-07-R1 (08/2018) 1 / 39 www.carlisleft.com

SERVICE MANUAL

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.

2 / 39 www.carlisleft.com

MANUAL CHANGES

PA-17-07-R1 (08/2018)

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 ABOUT THIS MANUAL

CONTENTS

SAFETY: 5-9

Safety Precautions ...................................................................................................................................................... 5

Hazards / Safeguards ................................................................................................................................................. 6

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

INTRODUCTION: 17-22

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

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

MANUAL CHANGE SUMMARY: 39

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

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CONTENTS

CAUTION

WARNING

NOTE

SAFETY PRECAUTIONS

Before operating, maintaining or servicing any

Carlisle Fluid

Technology MS Powder electrostatic coating system

, read

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.

A WARNING! states information to alert you to

a situation that might cause serious injury if

instructions are not followed.

A CAUTION! states information that tells how to

prevent damage to equipment or how to avoid a

situation that might cause minor injury.

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.

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.

The hazards shown on the following pages may

occur during the normal use of this equipment.

SAFETY

Repairs may only be performed by authorized personel.

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SAFETY

AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Spray Area 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.

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.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the 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.

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 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.

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.

Improper operation or

maintenance may create

a hazard.

Personnel must be properly

trained in the use of this

equipment.

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.

General Use and

Maintenance

Spray Area Explosion Hazard

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SAFETY

AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Spray Area /

High Voltage

Equipment

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.

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.

Electrical Discharge

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SAFETY

AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

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.

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.

Electrical Discharge

Electrical

Equipment

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.

Chemical HazardToxic Substances

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SAFETY

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.

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.

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

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.

EUROPEAN ATEX DIRECTIVE 2014/34/EU, ANNEX II

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ATEX

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