Carlisle ms 8160 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: 8160XX
MS Reciprocator MSR
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EN
SERVICE MANUAL

CONTENTS
SAFETY: 3-7
Safety Precautions .................................................................................................................................................... 3
Hazards / Safeguards ................................................................................................................................................ 4
PRODUCT OVERVIEW: 8-11
MS Reciprocator MSR Lengths ................................................................................................................................. 8
Specications ...........................................................................................................................................................11
INSTALLATION: 12
Transportation of the Reciprocator ........................................................................................................................... 12
Assembling Reciprocator Onto Base ...................................................................................................................... 12
OPERATION: 13-15
Control Box .............................................................................................................................................................. 13
Electrical Schematic - Siemens ............................................................................................................................... 14
Electrical Schematic - Allen Bradley ........................................................................................................................ 15
MAINTENANCE: 16-18
Maintenance Schedule ............................................................................................................................................ 16
Control Box Filter Inspection ................................................................................................................................... 16
Areas to Clean and Inspect ..................................................................................................................................... 18
General Fastener Torque Reference Guide ............................................................................................................ 18
PARTS IDENTIFICATION: 19-28
MS Reciprocator MSR ............................................................................................................................................. 19
MSR Bearing Bracket Assembly .............................................................................................................................. 20
MSR Weight Truck Assembly .................................................................................................................................. 21
MSR Motor 1000-3000 ............................................................................................................................................. 22
MSR End Stop Assembly ........................................................................................................................................ 23
MSR Motor 1000-3000 ............................................................................................................................................ 24
MSR Pulley Bracket Assembly 1000-3000............................................................................................................... 25
MSR Toothed Belt..................................................................................................................................................... 26
MSR Set Dirt Guard ................................................................................................................................................. 26
MSR Track Roller Prole .......................................................................................................................................... 26
MSR Motor Cover Hood ........................................................................................................................................... 26
MSR Guide Prole.................................................................................................................................................... 27
MSR Rear Cover Plate............................................................................................................................................. 27
MSR Holder.............................................................................................................................................................. 27
Recommended Spare Parts ..................................................................................................................................... 28
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CONTENTS
EN

CAUTION
!
WARNING
!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any electrostatic
coating system , read and understand all of the technical
and safety literature for your 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 asscoiated equipment
manuals to reconcile such differences.
WARNING
!
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 personnel.
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 equipment, contact your local
Carlisle Fluid Technologies representative or Carlisle Fluid
Technologies technical support.
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SAFETY
EN

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, 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
EN

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 I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
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 50176.
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, EN 60079-0.
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
EN

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.)
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 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 ushing,
cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Avoid installing an applicator into a uid system
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
Electrical Discharge
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SAFETY
EN

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 I or II, Division 1 and 2 hazardous areas in
accordance with NFPA-33 and EN 50176.
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
Spray applicators require that aluminum inlet ttings
be replaced with stainless steel.
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
solvents must never be used with aluminum
equipment during spraying, ushing, or cleaning.
Read the label or data sheet for the material you
intend to spray. If in doubt as to whether or not a
coating or cleaning material is compatible, contact
your coating supplier. Any other type of solvent may
be used with aluminum equipment.
Halogenated hydrocarbon
solvents for example:
methylene chloride and 1,1,1,
- Trichloroethane are not
chemically compatible with the
aluminum that might be used
in many system components.
The chemical reaction
caused by these solvents
reacting with aluminum can
become violent and lead to an
equipment explosion.
Explosion Hazard —
Incompatible Materials
Spray Area
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SAFETY
EN

The MS Reciprocator (Hereinafter refered to as MSR)
enables vertical up and down movement and has been
designed for automatic powder coating.
Spray guns, with Z-axis options can be mounted in
horizontal and vertical arrangement.
A worm gear motor (1) drives the lower pulley (3), the
toothed belt (2) and mounted carriage (5), with the spray
guns, moves up and down in the vertical direction.
The carriage runs on a precise guide rail (7).The guided
weight carriage (6) holds the load in balance.
With the upper (9) and lower limit switch (8) the maximum
stroke adjustment is limited and serves as a safety limit
switch. The incremental encoder (11) tracks the exact
position of the carriage at any point in time. The stroke,
speed and switching points can be entered via the control
module.
The MSR is controlled and adjusted via the system
control. The settings vary depending on the system.
PRODUCT OVERVIEW
3
2
1
11
6
4
9
7
5
8
MS RECIPROCATOR MSR LENGTHS
Standard MSR Sizes Stroke Length (mm)
MS Reciprocator MSR 1400 1-1400 2310
MS Reciprocator MSR 2000 1-2000 2910
MS Reciprocator MSR 2400 1-2400 3310
MS Reciprocator MSR 2800 1-2800 3710
Total Length (mm)
12
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PRODUCT OVERVIEW
EN

The MSR can be equipped with different bases and gun
supports. Depending on how the tower is integrated into
the system.
• Horizontal arrangement
• Vertical arrangement
• Single with axis motor
• Refer to powder gun service manual for additional,
detailed information
Y
Z
Y
Z
YY
Horizontal gun position with long stroke and high bar
sliding table.
Horizontal gun position with long stroke and oor base
without rail, with 2 xed and guide roller.
Horizontal gun position with long stroke and oor sliding
table transversely.
Horizontal gun position with long stroke and oor base
without cross rail, with 2 xed and guide roller.
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PRODUCT OVERVIEW
EN

Y
Z
Horizontal gun position with long stroke and MS Base.
Y
Vertical gun position with Z-axis.
Vertical gun position with vertical stroke and MS Base.
Z
Z
Z
Y
Vertical gun position with long sliding table.
Z
Y
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PRODUCT OVERVIEW
EN

Mechanical:
Lifting Speed: 1-55 m/min
Acceleration: 0.05-2.0 m/s²
Position Detection: Incremental encoder
Max. Lifting Wweight: 80 kg (see graphic)
SPECIFICATIONS
Electrical:
Drive: Worm gear motor
Power: 0.75 kW
Protection Type: IP54 ATEX Zone 22 Ex II 3D T85 °C
Isolation Class: F
Voltage: 480v / 60Hz
Kg
80
60
40
20
500 1000 1500 2000 PVS
350 350
400
610 450
450
257
4401400470
2310
273
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PRODUCT OVERVIEW
EN

INSTALLATION
The MSR is delivered in pieces to the installation facility.
The assembly is done by the technical personnel of Carlisle
Fluid Technologies. Each booth is constructed system
dependent.
Each specied protective measure must be observed for
all transport, handling and assembly work.
The MSR should not be installed in rooms subject to high
temperature. Partly gellable powder must be stored in a
cool area. Refer to powder coating manufacturer data for
detailed specications on storage requirements.
Base
The lifting unit is placed on a base to move. These are
available in the following variants:
• With integrated motor
• To move by hand
• Fix assembled
• Refer to base service manual for additional, detailed
information
Transportation of the Reciprocator
WARNING
!
Attention: To avoid damage to the lifting unit
• Do not place reciprocator on the front cover or the
front drive unit
• No loading on trucks.
F
E
LOCKING SCREWS (4X)
LOCKING NUTS
LOCKING SCREWS
TRACK ROLLER
Assembling Reciprocator onto Base
• Mount (2) threaded M16 eyebolts at top of
reciprocator tower (E).
• Lift reciprocator tower at eyebolts, set onto base,
and secure it with provided screws (F).
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INSTALLATION
EN

OPERATION
CONTROL BOX
Electrical breakers are in circuit with the reciprocator and
base drivers. The fuses labeled FU116 are in circuit with
the reciprocator driver MSC116. The fuses labeled FU216
are in circuit with the base driver MSC216.
There is a control box on either side of the booth, one for
each reciprocator/base unit.
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OPERATION
EN

L3L1 L2 PE 1 2 +DCBR -DC 22 23 24 25 26
WU V PE
27 28 29 30 31
0VDC
24VDC
BR
-DC
+DC
0VDC
24VDC
Dig. I/O 3
Dig. I/O 3
Dig. I/O 3
DI 4
DI 5
DI 6
0V
Drive Enable
ETH 1
ETH 2
Control Techniques Unidrive M700
AI 3
OV
OVDC
Input
Inv. Input
+10V
AI 2
A0 1
A0 2
0V
811 63 5 4 7 10 21 419 42
-K6.0
Drive Ok
-W6.3
107 108
4 5
-X6.3
22 22 21 21
-S6.3 -S6.4
-W6.3
6
/5.2 /5.2
/7.2 /7.2
-DC
+DC
-DC
+DC
/5.0 Not Aus 24VDC
-X6.3
109
M
3~
-T6.1
-M6.0
0.37KW
-W6.0.1
1 2 3 U V W
PE rc
-W6.1
Base 1 Achse 3
D-Sub HD 1Spol female
ELECTRICAL SCHEMATIC - SIEMENS
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OPERATION
EN

ELECTRICAL SCHEMATIC - ALLEN BRADLEY
2171
200 201 202 203 204 205 206 207 208 209 210
211
212 213 214 215 216 217 218 219 220 221
2161 2151
CAB113
STO1 STO2
0VDC
2173 2163 2153
MSC 216
ENCODER
BR+ BR-
8 PIN
M12 CABLE
ENCODER MOUNTED TO
REAR MOTOR SHAFT
REAC 216
2172 2162 2152
L3L2L1
FROM 125 FROM 125 FROM 125
STO1 STO2 0VDC 24VDC
S1 S2 S+ R1 R2 R5 R6 01 02 03 04 11 12 13 14
SAFE OFF STATUS OUTPUT
DIG COM
DIG IN1
DIG IN2
DIG IN3
24V
10 Vdc
+10/-10
Vdc Input
AN COM
8.8
V+ CM A+ A- B+ B- Z+ B- ENCODER INTERFACE CARD
A-B POWERFLEX 527
VARIABLE FREQ DRIVE
25C-D4PON104
IP: SEE MAIN CONTROLS
C1 C2
ETHERNET PORT
ETHERNET PORT
1321-3R4-B
FNQR 10 FNQR 10 FNQR 10
FU 216
OT_F OT_R
125
24VDC
(1)
OT_F
(2)
OT_R
(3)
FORWARD OVERTRAVEL
LS 205
REVERSE OVERTRAVEL / HOME
LS 206
1-BRN
2-WHT
3-BLU
4-BLK
5-GRY
6-PNK
7-VIO
8-ORG
ENC 210
MTR 216
VERTICAL RECIPROCATOR MOTOR
480 VAC. 0.5HP. 1.1 FLA
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OPERATION
EN

MAINTENANCE
MAINTENANCE SCHEDULE
Component Action Frequency
MAINTENANCE SCHEDULE
Maintenance schedule below is a general guide. Please
note that the components, action, and frequency
may vary depending on a variety of factors specic to
your application and facility. Maintaining cleanliness,
understanding of equipment, and training personnel will
reduce downtime relating to failed components.
Counter Weight Check Fastener Tension 6 Months
Toothed Belt Check Tension 6 Months
Replace As Needed
Guide Rails Clean 6 Months/As Needed
Control Box Filters Check & Clean Weekly
Gun Mounting Assembly Check Fastener Tension 6 Months
CONTROL BOX FILTER
INSPECTION
1. Inspect reciprocator control box lters for powder build-
up. If accumulation occurs and is not remedied, it can
lead to overheating of components.
2. Carefully use a at tool to pry lter cover off.
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MAINTENANCE
EN

Once cover is off, grasp and remove lter for inspection.
Use vacuum cleaner or low pressure blow off gun to
remove any powder accumulation.
Firmly place lter back into frame.
Press cover onto frame to reinstall.
CONTROL BOX FILTER
INSPECTION (Cont.)
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MAINTENANCE
EN

12.9
4.6
Strength Marking 4.8 8.8 and 9.8 10.9
Max Torque Max Torque Max Torque Max Torque Max Torque
Ft/Lbs Ft/Lbs Ft/Lbs Ft/Lbs Ft/LbsDiameter Wrench Size
M3 5.5mm 0.3 0.5 1 1.5 1.5
M4 7mm 0.8 1 2 3 4
M5 8mm 1.5 2 4.5 6.5 7.5
M6 10mm 3 4 7.5 11 13
M8 13mm 7 1 18 26 33
M10 16mm 14 18 37 55 63
M12 18mm 26 33 63 97 111
M14 21mm 37 55 103 151 177
M16 24mm 59 85 159 232 273
M18 27mm 81 118 225 321 376
M20 30mm 118 166 321 457 535
M22 33mm 159 225 435 620 726
M24 36mm 203 288 553 789 926
M27 41mm 295 417 811 1154 1353
M30 46mm 402 568 1103 1571 1837
GENERAL FASTENER TORQUE REFERENCE GUIDE
Check for powder accumulation within channels of
reciprocator and clean off with compressed air or vacuum,
as needed.
Using a blow gun, direct compressed air at the
reciprocator area.
Use a sweeping motion while starting at the top and
working downward.
As working downward, blow off automatic guns.
AREAS TO CLEAN AND INSPECT
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MAINTENANCE
EN

PARTS IDENTIFICATION
Description
Item # Reference
1 Bearing bracket MSR 1 Page 16
2 Weight truck 1 Page 17
3 Motor MSR 1000 - 3000 1 Page 18
4 End stop MSR 2 Page 19
5 Lift truck MSR 1 Page 20
Pulley bracket MSR 1000 – 3000 2 Page 21
6 Toothed belt MSR 1 Page 22
7 Set dirt guard MSR 1 Page 22
8 Track roller prole MSR 1 Page 22
9 Motor cover hood MSR 1 Page 23
10 Guide prole MSR 2 Page 23
11 Cover plate behind MSR 1 Page 23
12 Cover plate ahead MSR 1 Page 23
13 Holder MSR 1 Page 24
Qty
MS RECIPROCATOR MSR
11
2
4
1
13
12
5
6
3
10
2
8
9
11
7
13
9
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PARTS IDENTIFICATION
EN

Description
Reference # Part #Qty
MSR BEARING BRACKET ASSEMBLY
4
3
5
2
1
1 Angle bearing block MSR 2 448670
2 Spacer ring bearing block MSR 2 446307
3 Locking ring 1 446591
4 Bolt bearing block MSR 1 446304
5 Crown gear bearing block AT10 25 1 446301
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EN PARTS IDENTIFICATION