MS Topcoater 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: 805600 (Single), 805650 (Dual)
MS Topcoater Speedy
Powder Spray System
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EN
SERVICE MANUAL

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 / Safeguards ................................................................................................................................................ 6
INTRODUCTION: 10-18
Product Description .................................................................................................................................................. 10
Parts Breakdown .......................................................................................................................................................11
Building and Installation Topcoater........................................................................................................................... 12
Wiring Diagram of MS Topcase Control Module (Basic Model)................................................................................ 13
Spare Parts List - Topcoater..................................................................................................................................... 15
Applicator Powder Hose Set - Parts List .................................................................................................................. 16
Air Hose - Set Topcoater - Parts List ....................................................................................................................... 17
Description Individual Parts...................................................................................................................................... 18
MAINTENANCE: 19-31
MS Elite Injector (610015) - Parts List...................................................................................................................... 19
Cleaning Intake System (620101) - Parts List.......................................................................................................... 20
Suction Pipe Components - Parts List...................................................................................................................... 21
Product Description MS Topcase Control Unit S4.................................................................................................... 22
 Specications ........................................................................................................................................................... 23
Overview Front Corona Mode .................................................................................................................................. 24
Pneumatic Settings .................................................................................................................................................. 24
Electrical Settings..................................................................................................................................................... 25
Assignment of Keys.................................................................................................................................................. 25
Overview Front Tribo Mode ...................................................................................................................................... 26
Pneumatic Settings .................................................................................................................................................. 26
Assignment of Keys.................................................................................................................................................. 27
Overview Front Corona Modus in Nm3 .................................................................................................................... 28
Pneumatic Settings .................................................................................................................................................. 28
Electrical Settings..................................................................................................................................................... 29
Assignments of Keys................................................................................................................................................ 29
Connecting Hardware............................................................................................................................................... 30
Pin Assignment In/Output Connect .......................................................................................................................... 31
INSTALLATION: 32-50
Commissioning and Operation of MS Topcoat S4 Control Module .......................................................................... 32
Switch on the Topcase.............................................................................................................................................. 33
Service on the Manual Powder Gun......................................................................................................................... 36
Product Description .................................................................................................................................................. 40
 Specications ........................................................................................................................................................... 41
MS Topcoat M4 Manual Parts Breakdown ............................................................................................................... 42
Function.................................................................................................................................................................... 43
Function Nozzle........................................................................................................................................................ 44
Commissioning and Operation of MS Topcoat M4 Manual Powder Gun ................................................................. 45
Safe Handling of the Manual Powder Gun ............................................................................................................... 45
(Continued On Next Page)
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CONTENTS
EN

CONTENTSCONTENTS (Cont.)
PARTS IDENTIFICATION (Cont.): 32-50
Connecting ............................................................................................................................................................... 46
Connecting Manual Powder Gun ............................................................................................................................. 47
Connectable Controllers MS Topcoat Manual Powder Gun ..................................................................................... 47
Operation.................................................................................................................................................................. 47
Maintenance MS Topcoat M4 Manual Powder Gun ................................................................................................. 48
Nozzle Change......................................................................................................................................................... 48
Troubleshooting Guide ............................................................................................................................................. 50
DECLARATION OF CONFORMITY: 51
Decloration of Conformity......................................................................................................................................... 51
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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

INTRODUCTION
PRODUCT DESCRIPTION
The MS topcoater is a small stand-alone coating unit. The
trolley consists of a topcoat M4 manual powder spray gun,
a topcase S4 controller and a suction system.
In the lower part there is a vibrator, with this, the powder
can be moved and thereby raised better.
Optionally, the trolley can be equipped with a second control
device and a second manual powder spray gun, which are
supplied by a second suction system.
It is put into operation quickly through a simple structure
and is well suited for smaller coating installations. Through
the control connector at the topcase S4 control Unit, the
topcoatermayatanytimebeintegratedintoanexisting
plant or are simply placed as a pre-post-coating.
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INTRODUCTION
EN

PARTS BREAKDOWN
Description QuantityPart #
WARNING
!
Only use Powder Cable topcase US with 110V
vibrator motor.
615300-00 MS Topcase Control Unit S4 1
835069 MS Topcoat M4 manual gun 1
835015 Trolley Topcoater Single 1
835019 Trolley, Topcoater, Dual (Not Shown) 1
Four Power Cables are available (Included with Topcase):
460147 Power Cable topcase EU (Included in 615300-01) 1
460148 Power Cord CH (Included in 615300-04) 1
460150 Power Cable topcase CN (Included in 615300-03) 1
461881 Power Cord UK (Included in 615300-05) 1
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INTRODUCTION
EN

BUILDING AND INSTALLATION TOPCOATER
1 Manual Gun
2 Injector
3 Control Module
4 Suction System
5 Holder Topcoat M4
6 Solid Tire
Item # Description
TOPCOATER - PARTS LIST
Item # Description
7 Rubber Bummper
8 Hose Bracket
10 Vibrator Motor
12 ExtensionHolder
14 Cleaning Unit
2
7
5
8
6
14
4
1
3
12
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INTRODUCTION
EN

WIRING DIAGRAM OF MS TOPCASE CONTROL MODULE
(BASIC MODEL)
6 bar Inlet
Air Pressure
Vibrator Control
Signals 24VDC
230/110V
50/60Hz
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INTRODUCTION
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1
WARNING
!
WARNING
!
When connecting to ground, please read all
safety hazard warnings.
The air must be free of water and oil.
1. Feed air
2. Dosage air
3. Powder hose
Implementing
For commissioning the Topcoater it needs a 230V outlet, a
good conductive ground connection and an air connection
with 6 bars.
1. Check all powder hose and electrical cable connections.
2. Connect the ground wire to true earth ground.
3. Plug the connecting cable.
4. Connect air supply to Topcase and injector.
5. Place the powder container on the cart. Lower the
suction tube into the powder.
6. After reading the manual, switch on the Topcase
controller.
3
2
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INTRODUCTION
EN

SPARE PARTS LIST- TOPCOATER
Spare Parts Trolley Box
WARNING
!WARNING !
Pos. 2 vibrator 230 VAC 50 Hz with capacitor
may be different depending on the existing power
supply. Please contact MS Service.
The black air hoses for uid air, dosage air and
feed air are electrically conductive. They serve the
grounding of the powder injector and the suction sys-
tem. Replace the black air hoses only with original
spare parts.
4
3
1 620210 TrolleyTopcoaterEliteBox 1
2 620240 Vibration Motor Topcoater 230 V 1
3 443930 Solid Tire D200mm 2
4 806000 MS Suction System Elite 1
5 615300 MS Topcase Basic Unit 1
6 835069 MS Topcoat M4 1
Item # QuantityDescription
TROLLEY BOX - PARTS LIST
Part #
2
5
6
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INTRODUCTION
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1
4
3
2
Item # Wear PartDescription
POWDER HOSE SET TOPCOATER (610138-XX) - PARTS LIST
Part #
1 810195-XX Powder Hose 10/15.5 Antistatic (/m) W
2 461742-XX Hand Gun Cable, Topcoat M4
3 421370-XX Gun Air Hose
4 620120 Velcro Bands
Available Gun Cable and Powder/Air Hose lengths and ordering
information is available in manuals for the respective applicators
(PA-17-06 and PA-17-07).
APPLICATOR POWDER HOSE SET
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INTRODUCTION
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Item # Wear PartDescription
AIR HOSE - SET TOPCOATER (610144) - PARTS LIST
Part #
1 615235 Antikink Hose Ass’y
2 615236 Antikink Hose Ass’y
All Hoses lengths are (/m). When ordered as a complete assembly 610144, the hoses will be shrink wrapped together.
1
AIR HOSE - SET TOPCOATER
2
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INTRODUCTION
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The pictured
relate setting to
the coating with
the MS topcase
Control Unit S4
The settings are
dependent of the
powder.
450.0 g
400.0 g
350.0 g
300.0 g
250.0 g
200.0 g
150.0 g
100.0 g
50.0 g
0.0 g
0 Nm3/h 3 Nm3/h 4 Nm3/h 5 Nm3/h 6 Nm3/h
5%
100%
WARNING
!
DESCRIPTION INDIVIDUAL PARTS
Elite Injector - 1.7mm
Description
The Elite Injector is used in the powder coating to the airless,
continuous precisely adjustable powder feed.
Technical Data
Connecting and operating the Elite Injector and
the safety are to be observed in the operating instruc-
tions for the corresponding MS ECUs described.
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INTRODUCTION
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WARNING
!
The wear parts marked in the spare parts list
with (W) must be checked regularly and replaced
if necessary.
1 Main Body Intake System Elite 1 426636
2 InternalToothLockingWasherM9x14 2  421430
3 SetScrewM6x1 1 W 413162
4 Dosing Nozzle with O-Ring 1 620257
5 Powder Plug 1 426638
6 Lock Nut Intake 1 426639
7 Q.D. Male 1/8” BSPP 1 426030
8 Hose Nipple 1/8” BSPP 1 412332
9 O-Ring (Included in 620257) 1 417223
Item #
MS ELITE INJECTOR (610015) - PARTS LIST
Part #Description Quantity Wear Part
8
7
2
1
4
9
5
6
MAINTENANCE
3
2
MS Elite Injector (610015)
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EN MAINTENAMCE

1 Housing, Top 426655
2 Housing, Bottom 426656
3 Push to Connect Elbow Plug-In 10mm to 8mm 415742
4 Piston 426657
5 O-Ring,19.5x3.0,FKM 411342
6 O-Ring,20.35x1.78mm 445140
7 Push to Connect Fitting Male Elbow 10mm Tube Male 1/8” BPST 423450
8 Spring 450198
9 Metric18-8StainlessSteelSocketHeadScrewsM5x0.8mm 445111
10 Lock Washer for M5 Screw 425330
11 M6x60SocketCapHexScrew 439197
12 O-Ring,19x2.5mm 434202
Item #
CLEANING INTAKE SYSTEM (620101) - PARTS LIST
Part #Description
10
8
10
2
7
12
6
Cleaning Intake System - 620101
5
9
11
1
4
3
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MAINTENAMCE
EN