Carlisle MS Elite A5 User manual

EN
SERVICE MANUAL
PA-18-01-R5 (02/2022) 1 / 41 www.carlisleft.com
Model: 835020
2813 ll 2D 2mJ
MS Elite A5 Automatic Powder
Spray Applicator

MANUAL CHANGES EN
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NOTE: This manual has been changed from revision PA-18-01-R4 to revision
PA-18-01-R5. Reasons for this change are noted under “Manual
Change Summary” inside the back cover of this manual.

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CONTENTS
EN
CONTENTSCONTENTS
SAFETY: 4-12
Safety Precautions ........................................................................................................................................................4
Hazards / Safeguards ....................................................................................................................................................5
Intended Use .................................................................................................................................................................9
Notice of Harmless Discharge .....................................................................................................................................10
Safety Considerations ................................................................................................................................................. 11
Notes of Safety Hazards ............................................................................................................................................. 11
ATEX/FM/UKEX: 13-16
European ATEX Directive.............................................................................................................................................13
Label.............................................................................................................................................................................15
Approvals ATEX / FM / UKEX ..................................................................................................................................... 16
SPECIFICATIONS: 17
Specications ...............................................................................................................................................................17
INTRODUCTION: 18-21
Product Description .....................................................................................................................................................18
MS elite A5 Automatic Powder Applicator Parts Breakdown ....................................................................................... 19
Function .......................................................................................................................................................................20
Nozzle Function ...........................................................................................................................................................21
INSTALLATION: 22-28
Commissioning and Operation of Topcaot A5 Automatic Powder Applicator ............................................................... 22
Safe Handling of the Automatic Powder Applicator .....................................................................................................22
Cable and Hose Connections.......................................................................................................................................23
Wiring Diagram of MS elite Control Module (Basic Model) .......................................................................................... 24
Wiring Diagram of MS elite Control Module (Deluxe Model)........................................................................................ 25
Tubing Diagram For Use With 610190-10.................................................................................................................... 26
Connecting Automatic Powder Applicator .................................................................................................................... 27
Connectable Controllers MS elite Automaic Powder Applicator ................................................................................... 27
OPERATION: 28
Grounding ....................................................................................................................................................................28
MAINTENANCE: 29-32
Schedule ......................................................................................................................................................................29
Nozzle Change ............................................................................................................................................................29
Cleaning Powder Passage ...........................................................................................................................................30
Troubleshooting Guide .................................................................................................................................................32
PARTS IDENTIFICATION: 33-40
MS elite A5 Automatic Applicator Spare Parts .............................................................................................................33
Accessories ..................................................................................................................................................................34
Flat Nozzle Extensions.................................................................................................................................................36
MANUAL CHANGE SUMMARY: 42
Manual Changes .........................................................................................................................................................42

SAFETY EN
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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 associated 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 16985
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 personnel authorized by
Carlisle Fluid Technologies.
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
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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 16985, 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 (25mm) 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
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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
(25mm) 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, zone
20, 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 16985.
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
EN
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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 megohm. (Refer to NFPA-33,
EN 16985)
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 hand applicator,
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 16985 OR SPE-
CIFIC 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 I or II , Division 1 or 2, zone 20, 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 EN
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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, zone 20, 21 or zone
22 hazardous areas in accordance with NFPA-33
and EN 16985.
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 DischargeElectrical
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. Reference
EN 12215 or applicable code.
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
EN
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WARNING
!
CAUTION
!
WARNING
!
INTENDED USE
1. The MS eliteA5Automatic powder applicator 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 eliteA5Automatic powder applicator
or its operating conditions are altered, or materials differing
from the manufacturer’s specications are to be used,
the written consent of Carlisle Fluid Technologies must
be obtained.
3. Intended use also includes compliance with the
manufacturer's operating, maintenance and service
instructions. The MS eliteA5Automatic powder applicator
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
eliteA5Automatic powder applicator 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 elite A5 Automatic
powder applicator 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.
EN 50177 IP64 T6 (Zone 21)
Explosion
Protection
Protection
Class
Max Surface
Temperature
Safety Regulations for Electrostatic
Powder Coating
1. All conductive items in the spray area must be grounded
to true earth ground with a resistance of no more than
1 mega ohm measured at 250V minimum.
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).
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.
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 operator must ensure that the manual powder
coating equipment and accessories are tested as
required, this should be done at least annually by an
expert on safe working condition.
2813 ll 2D 2mJ
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SAFETY EN
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4. The supplied grounding cable (green / yellow) must be
connected to the grounding screw of the electrostatic
manual 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 true earth ground. The provided powder hose
must be used as it provides ground to the applicator.
5. The voltage and powder feed lines to the powder
applicators must be protected against mechanical,
thermal and chemical damage.
6. 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.
7. The booth air must be interlocked with the controller of
the powder applicator. If the booth is switched off the
controller is off.
8. The powder spray applicator may only be operated in
a powder spray enclosure with industrial ventilation.
Operation creates a hazard zone around the powder
spray applicator. (Reference EN 16985: 2018 NFPA-33)
9. 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).
10. The powder spraying equipment should be checked
annually by the operator for explosion protection.
11 . 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).
12 . When cleaning the powder applicator and when replacing
the nozzles, the controller must be switched off.
13. 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 true earth ground.
14. Powder must be used according to the manufacturer’s
instructions.
15. When disposing of powder and cleaning agents,
manufacturer’s instructions and the applicable
environmental protection regulations must be observed.
16. In the case of damage (broken parts, cracks, etc),
these components should be removed and the powder
applicator no longer operated.
17. Repairs may not under any circumstances be carried
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
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