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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

PA-17-06-R1  (08/2018)

1 / 37

www.carlisleft.com

EN

SERVICE MANUAL

Summary of Contents for Topcoat A4

Page 1: ...fully 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 PA 17 06 R1 08 2018...

Page 2: ...een 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...

Page 3: ...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 4: ...TION 20 24 Product Description 20 Specifications 21 Parts Breakdown 22 Wiring Diagram 23 Function 23 Nozzle Function 24 INSTALLATION 25 26 Commissioning and Operation of Topcoat A4 Automatic Powder Gu...

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: ...the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer s documentation 8 The certification of this equipment relies upon the following materials used in its co...

Page 11: ...X Special conditions for safe use apply Ex Specific marking of explosive protection II Equipment Group hazardous area characteristics 2 Equipment Category D Type of explosive atmosphere dust EEx2mJ Th...

Page 12: ...WIRING DIAGRAM OF MS TOPCASE CONTROL MODULE BASIC MODEL 6 bar air inlet pressure Vibrator Control Signals 24VDC 230 110V 50 60Hz PA 17 06 R1 08 2018 12 37 www carlisleft com ATEX EN...

Page 13: ...WIRING DIAGRAM OF MS TOPCASE CONTROL MODULE DELUXE MODEL 6 bar air inlet pressure Vibrator Control Signals 24VDC 230 110V 50 60Hz PA 17 06 R1 08 2018 13 37 www carlisleft com ATEX EN...

Page 14: ...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 In...

Page 15: ...losion 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...

Page 16: ...cording to the manufacturer s instructions 15 When disposing of powder and cleaning agents manufacturer s instructions and the applicable environmentalprotectionregulationsmustbeobserved 16 Inthecaseo...

Page 17: ...ed in perfect condition 6 Wherenecessary theenduserwillprovidetheoperator with protective clothing e g face mask 7 The user must ensure cleanliness and clarity of the workspace at and around the powde...

Page 18: ...l parts Additional measures such as barriers shall be taken to prevent unauthorized access Prohibition of unauthorized conversions and modifications to the machine Any unauthorized modifications or ch...

Page 19: ...e 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 Gener...

Page 20: ...he optimum level of safety and efficiency The system is incapable of releasing sufficient electrical or thermal energyduringnormaloperatingconditionstocauseignition of specific hazardous materials in...

Page 21: ...uality 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 Conditi...

Page 22: ...e 4 Flat spray nozzle 5 Clip Body 6 9 Pin Electrical M12 Connector 7 4mm ODT Fitting 8 Powder Hose Connector 9 Screw M4 x 6 Nylon 10 Screw M4 x 10 Nylon 6 6 3 4 1 2 7 8 5 6 9 10 Figure 1 MS Topcoat A4...

Page 23: ...ating gun generates an electric field 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...

Page 24: ...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 Gun Air High Voltage High...

Page 25: ...peration of this device before switching it on DO NOT touch the gun nozzle when high voltage is switched on Do not stand in front of the spray gun Connecting Automatic Powder Gun The powder hose conne...

Page 26: ...eaks in the connectors 5 Turnoffthepowertothepowdergunusingthecontroller 6 Attach the powder hose to the back of the gun 7 Turn on the powder gun using the controller and check for leaks in the powder...

Page 27: ...sabove1MOhm thehangersshouldbecleaned more frequently than one week The powder hose must have a resistance of less than 1 MOhm Important 1 Powder residues must be regularly cleaned from hangers 2 The...

Page 28: ...h 3 4 1 2 1 3 4 2 SCHEDULE Daily or at start of each shift Verify all containers in hazardous area and spray area are grounded Check within 6m 20ft of the point of operation of the applicator and remo...

Page 29: ...tive fuse on the controller Error at the high voltage generation Defective Cascade in spray gun Defect electric cable from gun to Controller Incomplete grounding No grounding Compressed air main suppl...

Page 30: ...e Tube W 615024 Assembly Nozzle Holder W 615260 01 Electrode Wire Assembly Flat Spray 615219 01 Pressure Bar 615028 Flat Spray Nozzle C3 W 615083 Flat Jet Nozzle G4 W 615057 Powder Connector with O Ri...

Page 31: ...in 615254 460425 Round Spray Nozzle D12 Included in 615254 Part FLAT SPRAY NOZZLE Description 615040 Assembly Flat Spray Nozzle Electrode 615028 Assembly Nozzle Included in 615040 615281 Assembly Fla...

Page 32: ...95 08 Powder Hose 8m 10mm ID 810195 10 Powder Hose 10m 10mm ID 810190 16 Powder Hose 16m 11mm ID 810195 100 Powder Hose 100m Bulk 10mm ID 810190 20 Powder Hose 20m 11mm ID 810190 100 Powder Hose 100m...

Page 33: ...on A4 Topcoat L 1000mm Part GUN AIR HOSE Description 421370 06 Tube 6m 4mm OD 2 5mm ID 421370 08 Tube 8m 4mm OD 2 5mm ID 421370 10 Tube 10m 4mm OD 2 5mm ID 421370 16 Tube 16m 4mm OD 2 5mm ID 421370 20...

Page 34: ...particular 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 respon...

Page 35: ...PTB EU TYPE EXAMINATION CERTIFICATE PA 17 06 R1 08 2018 35 37 www carlisleft com EN PARTS IDENTIFICATION...

Page 36: ...he table 15 6 Update text for bullet point number 9 16 7 Change text in lines 3 4 and 16 19 8 Change both Output Voltage and Output Current in SPECIFICATIONS 21 9 Update drawing and table 30 10 Remove...

Page 37: ...n innovative finishing technologies Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice DeVilbiss Ransburg MS BGK and Binks are registered trademarks...

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