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
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EN
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.
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MANUAL CHANGES
EN
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
EN

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
!
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
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, 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
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 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
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,
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
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 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
EN

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.
2. 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.
3. Installation shall be carried out by suitably trained
personnel in accordance with the applicable code of
practice e.g. EN 60079-14:1997.
4. Inspection and maintenance of this equipment shall be
carried out by suitably trained personnel in accordance
with the applicable code of practice e.g. EN 60079-17,
EN 50050-1, EN 50177.
5. Putting into service, use, assembling, and adjustment
of the equipment shall be tted by suitably trained
personnel in accordance with the manufacturer's
documentation.
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:
8.
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
EN

MS Powder M4 Topcoat 835069 ATEX
Product Marking Denitions
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
Ex = Specic marking of explosive protection
II = Equipment Group hazardous area
characteristics
2 = Equipment Category
D = Type of explosive atmosphere (dust)
EEx 2mJ = The MS Powder M4Topcoat 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.
II 2 D
Product Marking
PTB 16 ATEX 5003
Ser. No: XXXX
Type: M4 Topcoat Voltage max 100kV
Current: 0.9A
0518 II 2D EEx 2mJ
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ATEX
EN

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 RL2014/34/
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.
Explosion
Protection
Protection
Class
Max Surface
Temperature
Safety Regulations for Electrostatic
Powder Coating
The legislator describes (ZH 1/443, section 6.1):
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.
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)
CAUTION
!
WARNING
!
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.
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 pow-
der coating equipment and accessories are tested as
required, this should be done at least annually by an
expert on safe working condition.
0518 II (2) D IP64 85°C IP64 T6 (Zone 22)
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ATEX
EN

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.
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.
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.
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.
18.
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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ATEX
EN

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.
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
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.
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.
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ATEX
EN

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.
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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ATEX
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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 2)
EN 50050-2: 2013 Electrical equipment for potentially explosive atmospheres - Electrostatic manual
powder coating equipment 2)
EN 50177 Stationary electrostatic spraying equipment for ammable coating powder 2)
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 2)
EN 60 204 identical: VDE guidelines for the electrical equipment of manufacturing and processing
machines with nominal voltages up to 1000V 3)
2006/42/EG Machine guidelines
EN 60204-1 Safety of machinery-electrical equipment of machines
2004/108/EG EMC Electromagnetic Compatibility Directive
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 1)
• Part 1 General requirements
• Part 2 Assembly examples
European Guidelines
International-regulations
*Sources
1) Carl Heymanns Verlag KG, Luxemburger Strasse 449, 5000 Köln 41 or competent for the member companies
Professional Association
2) Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30
3) VDE-Verlag GmbH, Bismarckstrasse 33, 1000 Berlin 12
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
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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.
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
Article #
SCOPE OF DELIVERY
Description
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.
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 givesATEX
EN 50 050-2: 2013.
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INTRODUCTION
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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
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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INTRODUCTION
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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
MS TOPCOAT M4 MANUAL PARTS BREAKDOWN
3
4
1
2
5
67
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WIRING DIAGRAM
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.
3
4
1
2
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INTRODUCTION
EN