MS Topcoat A4 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: 835070
MS Topcoat A4 Automatic
Powder Spray Gun
0518 II 2D 2mJ
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EN
SERVICE MANUAL

NOTE: This manual has been changed from revision PA-17-06-R0 to revision
PA-17-06-R1. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
2 / 37 www.carlisleft.com
MANUAL CHANGES
EN
PA-17-06-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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ABOUT THIS MANUAL
EN

CONTENTS
SAFETY: 5-9
Safety Precautions .................................................................................................................................................... 5
Hazards / Safegaurds ................................................................................................................................................ 6
ATEX/FM: 10-18
European ATEX Directive ........................................................................................................................................ 10
European ATEX Labels ............................................................................................................................................11
Wiring Diagram of MS Topcase S4 Control Module (Basic Model) ......................................................................... 12
Wiring Diagram of MS Topcase S4 Control Module (Deluxe Model)........................................................................ 13
Connecting .............................................................................................................................................................. 14
Intended Use ........................................................................................................................................................... 15
Notice of Harmless Discharge ................................................................................................................................. 16
Safety Considerations ............................................................................................................................................. 16
Notes of Safety Hazards ......................................................................................................................................... 17
Rules and Regulations ............................................................................................................................................ 19
INTRODUCTION: 20-24
Product Description ................................................................................................................................................. 20
 Specications .......................................................................................................................................................... 21
Parts Breakdown ..................................................................................................................................................... 22
Wiring Diagram ........................................................................................................................................................ 23
Function ................................................................................................................................................................... 23
Nozzle Function ....................................................................................................................................................... 24
INSTALLATION: 25-26
Commissioning and Operation of Topcoat A4 Automatic Powder Gun .................................................................... 25
Safe Handling of the Automatic Powder Gun .......................................................................................................... 25
OPERATION: 27
Grounding ................................................................................................................................................................ 27
MAINTENANCE: 28-29
Schedule ................................................................................................................................................................. 28
Nozzle Change ........................................................................................................................................................ 28
Troubleshooting Guide ............................................................................................................................................. 29
PARTS IDENTIFICATION: 30-35
MS Topcoat A4 Automatic Gun Spare Parts ............................................................................................................ 30
Accessories .............................................................................................................................................................. 31
Declaration of Conformity ........................................................................................................................................ 34
 PTBECTypeExaminationCerticate..................................................................................................................... 35
MANUAL CHANGE SUMMARY: 36
Manual Changes ..................................................................................................................................................... 36
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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50050-2,EN50177.
5. Repair of this equipment shall be carried out by
suitable trained personnel in accordance with the
applicablecodeofpracticee.g.EN60079-19.
6. 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
7. 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.
8. 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:
a. High voltage cascade is encapsulated with a solvent
resistant epoxy.
9.
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 A4 Topcoat 835070 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 A4 Topcoat applicator is suitable
for use in automatic spraying installations complying with
EN50050-2:2013asitisaTypeAclasswithadischarge
energy limit of 2mJ according to EN 50177.
II 2D
Product Marking
0518 II 2D EEx 2mJ
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ATEX
EN

WIRING DIAGRAM OF MS TOPCASE
CONTROL MODULE (BASIC MODEL)
6 bar air inlet
pressure
Vibrator Control
Signals 24VDC
230/110V
50/60Hz
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ATEX
EN

WIRING DIAGRAM OF MS TOPCASE
CONTROL MODULE (DELUXE MODEL)
6 bar air inlet
pressure
Vibrator Control
Signals 24VDC
230/110V
50/60Hz
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ATEX
EN

Connect
CONNECTING
To Notice From
Connect Controller
Connect ground GND Controller Signal ground Safety rules
(Yellow/Green) System ground
Main cable Line Power Main Controller Safety rules
Power Cable
Main air Main Air Main air Controller 6 bar
Oil and water free
Connecting to Controller
Manual powder gun cable Gun Connect Manual Controller
Powder Gun
Powder gun air hose Gun air Manual Controller
(Black) powder gun
Powder hose Powder Manual powder Powder hose
  injector gun connector
Quick release
Connect Powder Injector
Feedairhose FeedAir(blue) Controller Powderinjector
Dosageairhose DosageAir(red) Controller Powderinjector
WARNING
!
The plug of the pistols cable is equipped with a
nose, this has to be run in the groove of the sleeve.
The plug is tightened with 0.6Nm.
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ATEX
EN

INTENDED USE
1. The MS Topcoat A4Automatic powder gun is exclusively
for use in powder coating. It has been developed
according to recognized safety regulations for use in
potentially explosive atmospheres according to directive
RL 2014/34/EU.
2. Any other use is considered improper. The manufacturer
is not liable for any resulting damage. The risk lies by
the user alone. If the MS Topcoat A4 Automatic 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 Carlisle MS Powder must
be obtained.
3. Intended use also includes compliance with the
manufacturer's operating, maintenance and service
instructions. The MS Topcoat A4 automatic 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automatic
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. 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.
5. The voltage and powder feed lines to the powder guns
must be protected against mechanical, thermal and
chemical damage.
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 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) 3D IP64 85°C IP64 T6 (Zone 22)
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ATEX
EN

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. Set the exhaust system of the powder coating device
must also be switched off.
8. The powder spray gun may only be operated in a
powder spray enclosure with industrial ventilation.
Operation of the powder spray gun creates a hazard
zone around the powder spray gun.
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, EN 16985).
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 gun 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 less than .24mJ.
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 automatic
powder gun 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Oberächentechnikmay
be used.
NOTICE ON HARMLESS
DISCHARGES
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
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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 end user must ensure that the spray powder unit
is only operated in perfect condition.
6. Where necessary, the end user 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.
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 true earth of each
work piece must not exceed 1 Mega Ohm. 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.
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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 and the agency approval. 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
is no longer valid.
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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
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INTRODUCTION
PRODUCT DESCRIPTION
Application
The MS Topcoat A4 automatic powder gun is designed
exclusively for electrostatic coating with organic powders.
This powder gun is suitable for electrostatic coating of ob-
jectsofallshapesandgeometries,providedtheycanbe
grounded. The Topcoat A4 Automatic 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 A4 Auto-
matic 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, appli-
cator circuitry causes the high voltage to approach zero
while the current approaches its maximum value. This
performance is validated by independent test agencies
that give ATEX EN 50 050 approvals.
Foreseeable misuse
•Coatingofungroundedobjects
• Use of enamel powder
•Incorrectpowderowrates
•Incorrectelectrodeairowvalues
• Using moist powder
Part #
SCOPE OF DELIVERY
Description
835070 Topcoat A4
615040 (Included) Spray nozzle set
PA-17-06-R0 Manual with spare and wear parts list
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INTRODUCTION
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