MS 805600 Service Manual Download

Page: 30 / 52

Connector Name

CONNECTING HARDWARE

Notice

From

Control Module Connecting

Connect ground cable

GND (Yellow/Green)

Controller

True Earth Ground

Safety regulations

Main cable

Line Power

Main Supply

Controller

Safety regulations

Main air

Main Air Input

Main air

Controller

6-8 bar Free from

Oil and water

Connect control signals In/Output

Connect

Controller

Vibrator Motor

Safety regulations

Fuse

Prim. Fuse

2.5A (Pre Installed)

Connect Manual Gun

Manual powder gun

Corona

Manual

Controller

Cable, Corona

Gun Connect

Powder Gun

Manual powder gun

Tribo

Manual

Controller

Cable, Tribo

Gun Connect

powder gun

Gun air hose

Gun Air

Manual

Controller

(black)

powder gun

Connect Powder Injector

Air hose feed air

Feed Air (blue)

Controller

Powder injector

Air hose dosage air

Dosage Air (red)

Controller

Powder injector

Connect What

CAUTION

These units must be located outside the hazardous

area (zone 22, class 1 division 2)

PA-18-02-R0 (08/2018)

30 / 52

www.carlisleft.com

MAINTENAMCE

Summary of Contents for 805600

Page 1: ...lly 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 PA 18 02 R0 08 201...

Page 2: ...ks of their respective owners Inthismanual referenceismadetodifferenttrademarksorregisteredtrademarks Such references do not imply that the manufacturer in question approves this manual in any way or...

Page 3: ...view 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...

Page 4: ...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 5...

Page 5: ...drawings and appropriate MS Powder equipment manuals to reconcile such differences Careful study and continued use of this manual will provide a betterunderstandingoftheequipmentandprocess resulting...

Page 6: ...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 flammable...

Page 7: ...dvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Frequent power supply shutdown indicates a problem in the system which requ...

Page 8: ...re 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 vi...

Page 9: ...th NFPA 33 and EN 50177 EN 50050 2 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltage to be on but...

Page 10: ...Optionally thetrolleycanbeequippedwithasecondcontrol 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 struct...

Page 11: ...15 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...

Page 12: ...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...

Page 13: ...WIRING DIAGRAM OF MS TOPCASE CONTROL MODULE BASIC MODEL 6 bar Inlet Air Pressure Vibrator Control Signals 24VDC 230 110V 50 60Hz PA 18 02 R0 08 2018 13 52 www carlisleft com INTRODUCTION EN...

Page 14: ...nductive ground connection and an air connection with 6 bars 1 Checkallpowderhoseandelectricalcableconnections 2 Connect the ground wire to true earth ground 3 Plug the connecting cable 4 Connect air...

Page 15: ...onductive 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 Vibrati...

Page 16: ...c 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 resp...

Page 17: ...IST 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...

Page 18: ...3 h 5 Nm3 h 6 Nm3 h 5 100 WARNING DESCRIPTION INDIVIDUAL PARTS Elite Injector 1 7mm Description TheEliteInjectorisusedinthepowdercoatingtotheairless continuous precisely adjustable powder feed Technic...

Page 19: ...et 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...

Page 20: ...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 R...

Page 21: ...th O Ring 1 1 615127 3 O Ring 1 417188 4 Outer Tube with O Ring 3 1 615128 5 Suction Intake with O Ring 6 1 615126 6 O Ring 2 417186 7 Coupling Fitting 1 W 426633 WARNING The wear parts marked in the...

Page 22: ...ay gun The control unit automatically detects which type of gun is attached The MS topcase S4 control unit is suitable for our new even for our old models It has the following features Digital control...

Page 23: ...W Fuse 2 5A Permission Protection class IP 64 Interference suppression FN Temperature range 0 C 40 C 32 F 104 F PTB 16ATEX5004 EN50050 2 2013 Pneumatic data Input air pressure 6 bar Compressed air qua...

Page 24: ...r If a lot of powder output is desired the dosage air is set to be smaller 0 2 0 6 bar Setting the Gun Air The gun air is used to cool the electrode and for ven tilation of the baffle plate Settings f...

Page 25: ...must set higher In case of over coating or MDF coating the amount of current can be set low Approximately 8 10 A Bottom menu programs Switch to the Programs Bottom cleaning Start cleaning up for pres...

Page 26: ...the powder cloud If little amount of powder is desired the dosage air is set to be higher 0 6 1 6 bar If a lot of powder output is desired the dosage air is set to be smaller 0 2 0 6 bar 0 1 2 3 4 5 6...

Page 27: ...amount of current is set higher In case of over coating or MDF coating the amount of current can be set low Approximately 8 10 A NOTE NOTE In case of excessive amount of electricity produced orange pe...

Page 28: ...ed for setting the kinetic propulsion of the powder cloud Standard Setting 3 6Nm3 h4 Setting the Gun Air The gun air is used to cool the electrode and for ventilation of the baffle plate Standard Sett...

Page 29: ...proximately 70 kV Metallic powders are set about 50 60 kV Setting the current control Thecurrentregulationhasagreatinfluenceonthechargeon thepowder Asarule littleelectricityisused Approximately 20 A I...

Page 30: ...lations Fuse Prim Fuse 2 5A Pre Installed Connect Manual Gun Manual powder gun Corona Manual Controller Cable Corona Gun Connect Powder Gun Manual powder gun Tribo Manual Controller Cable Tribo Gun Co...

Page 31: ...2 0V DC 3 and 4 are not connected 5 Extern Start Corona 6 Extern Start Tribo 4 Extern Start Wash Earth 3 24V DC 1 Vibrator 230V AC 2 Vibrator 0V AC IN OUTPUT CONNECT IN OUTPUT CONNECT LINE POWER LINE...

Page 32: ...ting device must be electrically interlocked with the exhaust system of the powder coating The powder coating device must be switched on only when the cabin is running Set the air conditioning off and...

Page 33: ...keyboard will be called automatically Select Program After switching on the desired program must be selected For this pressthebuttonPROGRAMS Theprogram menuopens Select the Program by pressing the num...

Page 34: ...a name for the program Make sure that no programs are overwritten NEW PROGRAM PROGRAMS 4 Select the desired number and give the program a name By pressing on the field a keyboard will be called autom...

Page 35: ...tion of this manual and press the DELETE PROGRAM button Back To The Overview With the WORK button it s at any time possible to switch back to the work view home screen PROGRAMS DELETE PROGRAM SAVE PRO...

Page 36: ...ghts up At the controller module you can see the value Program Change by the Manual Powder Gun 0 1 2 3 4 5 6 0 10 20 30 60 70 100 40 50 80 90 0 10 20 30 60 70 100 40 50 80 90 0 1 2 3 4 5 6 bar bar A P...

Page 37: ...or can be set Standby Mode The powder applicator turns off with the OFF button When theOFFbuttonlightsupred workpiecescannotbecoated CAUTION If the powder is provided from an external source do not tu...

Page 38: ...sed for the second coating Area 2 Fluid Box And Cleaning In this area the specified setting of the fluid box and clean ing process can be set Setting The Injector Type Selectseithertheolderinjectortyp...

Page 39: ...t 1 Powder residues must regularly be cleaned off of workpiece hangers 2 Connect the grounding cable to the control unit WARNING Sparks between workpiece and hangers may arise if hooks or other hanger...

Page 40: ...opcoat M4 manual receives power from a controller which powers a cascade that generates a high voltage DC charge to the electrode creating an electrostatic field between the nozzle and the target One...

Page 41: ...ed 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...

Page 42: ...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 6 7 PA 18 02 R0 08 2018 42 52 www...

Page 43: ...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 fine cloud and de posited evenly on the grounded wor...

Page 44: ...through freely Flat fan nozzle The gun air is used to cool the electrode in the flat spray nozzle Round spray nozzle The gun air is used to cool the electrode and to ventilate the round spray nozzle H...

Page 45: ...nings COMMISSIONING AND OPERATION OF MS TOPCOAT M4 MANUAL POWDER GUN CAUTION NOTE Before you begin the installation and commissioning take a moment to familiarize yourself with the relevant manuals Ch...

Page 46: ...t 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...

Page 47: ...ct via a quick coupling This enables a rapid plugging and unplugging powder hose by a spring The electrical connection is permanently assembled 1 Quick disconnect button 2 Powder hose connection 3 Gun...

Page 48: ...n of powder 3 4 1 2 2 3 4 1 2 NOZZLE CHANGE Removing the nozzle 1 CleanthepowdergunasdescribedaboveinInterruption of work 2 Pull of nozzle 1 from the nozzle tube 3 WARNING Wear parts in the powder gun...

Page 49: ...s are clean and undamaged Do not clean the nozzles with solvent Under all circumstances the manual powder guns must be dismounted for cleaning Connection cable etc There can be no guarantee for the sa...

Page 50: ...ctor nozzle propelling nozzle in the injector Worn nozzle system Replace fuse Contact MS Service Contact MS Service Contact MS Service See chapter Grounding See chapter Grounding Check the air supply...

Page 51: ...ticular BGI 764 Identification Topcase M4 A4 PTB 16 ATEX 5004 PTB 16 ATEX 5003 IP64 85 C EN 50050 2 EN 50050 2 EN 50177 This Declaration of conformity incorporation is issued under the sole responsibi...

Page 52: ...arlisle Fluid Technologies Inc 2018 Carlisle Fluid Technologies Inc All rights reserved For technical assistance or to locate an authorized distributor contact one of our international sales and custo...

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