Related Manuals for Carlisle Ransburg LEPS5001
Summary of Contents for Carlisle Ransburg LEPS5001
- Page 1 SERVICE MANUAL Voltage Master 2 High Voltage Power Supply System Control Panel Model: 78789 Power Supply Model: LEPS5001 CP-02-02-R7 (10/2022) 1 / 47 www.carlisleft.com...
- Page 2 MANUAL CHANGES NOTE: This manual has been changed from revision CP-02-02-R6 to revision CP-02-02-R7. Reasons for this change are noted under “Manual Change Summary” inside the back cover of this manual. CP-02-02-R7 (10/2022) 2 / 47 www.carlisleft.com...
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Page 3: Table Of Contents
CONTENTS CONTENTS SAFETY: Safety Precautions ................................5 Hazards / Safeguards ..............................6 ATEX: 10-11 European ATEX Directive ............................10 European ATEX Labels ...............................11 INTRODUCTION: 12-15 General Description ..............................12 Specifications ................................13 Electrical Noise ................................14 Cable Connection Examples ............................15 INSTALLATION: 16-27 Block Diagram of Typical REA III Automatic Applicator Installation ................ - Page 4 CONTENTS CONTENTS (Cont.) MAINTENANCE: 35-39 General ..................................35 Overload Procedures ..............................36 Troubleshooting ................................36 Troubleshooting Guide ..............................38 PARTS IDENTIFICATION: 40-45 Control Panel Parts List - Front View ..........................40 Control Panel Parts List - Inside Door View .........................41 Control Panel Parts List - Inside View .........................42 78789 Control Panel Parts List ............................43...
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Page 5: Safety
This information relates to USER SAFETY and PREVENTING and safety literature for your equipment, contact your local EQUIPMENT PROBLEMS. To help you recognize this Carlisle Fluid Technologies representative or Carlisle Fluid information, we use the following symbols. Please pay Technologies technical support. -
Page 6: Hazards / Safeguards
SAFETY Return To Contents AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Spray Area Fire Hazard Fire extinguishing equipment must be present in the Improper or inadequate operation spray area and tested periodically. and maintenance procedures will cause a fire hazard. - Page 7 SAFETY Return To Contents AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Explosion Hazard Spray Area Improper or inadequate operation Electrostatic arcing must be prevented. Safe sparking and maintenance procedures will distance must be maintained between the parts being cause a coated and the applicator.
- Page 8 SAFETY Return To Contents AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Electrical Discharge Spray Area / High Voltage Parts being sprayed and operators in the spray area must be There is a high voltage device Equipment properly grounded.
- Page 9 SAFETY Return To Contents AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Electrical Discharge Electrical Equipment High voltage equipment is Unless specifically approved for use in hazardous locations, utilized in the process. Arcing the power supply, control cabinet, and all other electrical in the vicinity of flammable or equipment must be located outside or applicable country...
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Page 10: Atex
ATEX Return To Contents ATEX EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6 The following instructions apply to equipment covered by 8. The certification of this equipment relies upon the certificate number Sira 08ATEX5040X: following materials used in its construction: 1. The equipment may be used with flammable gases and If the equipment is likely to come into contact with vapors with apparatus groups II and with temperature aggressive substances, then it is the responsibility of... -
Page 11: European Atex Labels
ATEX Return To Contents Voltage Master 2 High Voltage Power Supply System ATEX Product Marking Definitions Ex Certificate Number: Sira 08ATEX5040X Sira = Notified Body performing EC-type examination 08 = Year of certification ATEX = Reference to ATEX Directive 5 = Protection Concept Code (code 5 is titled Encapsulation) 040 = Document serial number X = Special conditions for safe use apply... -
Page 12: Introduction
INTRODUCTION Return To Contents INTRODUCTION GENERAL DESCRIPTION The Voltage Master 2 high voltage power supply system • HV Cable includes a control panel and power supply unit in combination The Ransburg high voltage cable is specially formulated and to produce up to 100kV DC continuous operating voltage constructed to offer a maximum level of dielectric protection while delivering up to 1,500 microamps load current. -
Page 13: Specifications
INTRODUCTION Return To Contents SPECIFICATIONS Environmental/Physical Operating Temperature: 0°C to 45°C Storage Temperature: -40°C to 85°C Humidity: 85% non-condensing CONTROL PANEL Size: 20" H x 16" W x 8" D (50.8cm x 40.6cm x 20.3cm) Weight: 76 lbs. (20.4kg) Input Pressure: 100 psi max. -
Page 14: Electrical Noise
INTRODUCTION Return To Contents ELECTRICAL NOISE For maximum noise protection any user supplied input/ Electrical noise refers to stray electrical signals in the atmo- sphere at various signal strengths and frequencies that can output (I/O) wiring should be made using shielded cable or affect the operation of equipment. -
Page 15: Cable Connection Examples
INTRODUCTION Return To Contents Figure 1: Cable Connection Examples www.carlisleft.com 15 / 47 CP-02-02-R7 (10/2022) -
Page 16: Installation
INSTALLATION Return To Contents INSTALLATION Figure 2: Block Diagram Of A Typical Rea Iii Automatic Applicator Installation CP-02-02-R7 (10/2022) 16 / 47 www.carlisleft.com... -
Page 17: Block Diagram Of Typical Areobell 33 Installation
INSTALLATION Return To Contents Figure 3: Block Diagram Of A Typical Aerobell 33 Installation www.carlisleft.com 17 / 47 CP-02-02-R7 (10/2022) -
Page 18: Location
INSTALLATION Return To Contents LOCATION WARNING NOTE † To shorten the ground wire assembly, use a † The 78789 control panel and the LEPS5001 power screwdriver to remove the lug (at end opposite clamp) supply MUST be located outside the hazardous area from the end of the assembly, cut the wire to the length (see NFPA-33). -
Page 19: System Installation
INSTALLATION Return To Contents Figure 4: AC Power Input Connections SYSTEM INSTALLATION The 78789 control panel can be interfaced with Ransburg Air Logic Stations. Air Logic Stations send and receive pneumatic signals for the purpose of remote control from hazardous locations such as inside the spray booth. Contact your local Ransburg representative or customer support for more detailed information on the Air Logic Stations or additional control options. -
Page 20: 78789-Xx Control Panel Schematic
INSTALLATION Return To Contents Figure 5: 78789-Xx Control Panel Schematic CP-02-02-R7 (10/2022) 20 / 47 www.carlisleft.com... -
Page 21: Power Supply Connections
INSTALLATION Return To Contents POWER SUPPLY CONNECTIONS Route the control cable from the power supply tank through the connector opening labeled HV POWER SUPPLY at the top right of the control panel and connect to TB4 (see Fig- ure 6 for TB4 location) of the Mother Board printed circuit assembly as detailed in Table 1. - Page 22 INSTALLATION Return To Contents TABLE 1 - POWER SUPPLY CONNECTIONS Wire # Color To Control Panel White TB4-1 Black TB4-17 Black TB4-31 TB4-34 Shield Bare TB4-GND TABLE 2 - ELECTRICAL SYSTEM CONNECTIONS Description Terminal Number External HV ON (PLC or Panel Switch) TB2-3 to TB2-5 External HV OFF/RESET (PLC or Panel Switch) TB2-8, TB2-8A, TB2-9, TB2-10...
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Page 23: Ac Remote I/O
INSTALLATION Return To Contents AC REMOTE I/O High Voltage Setpoint Analog Input If required by the application, the following AC remote I/O connections can be made. The wiring for these connections When the front panel kV Local/Remote switch is in the Re- should be supplied through conduit to the REMOTE I/O mote position and high voltage is enabled, a 0 to 10 VDC or (AC) opening in the bottom left corner of the control panel. -
Page 24: Pneumatic Connections
INSTALLATION Return To Contents 5. Route the cable(s) back through the connector housing(s) and connect to TB3 (see Figure 6 for TB3 location) as detailed in Table 4. 6. Tighten the cable grommet ensuring the grommet spring makes 360° contact with the exposed braid of the cable for maximum noise immunity. -
Page 25: High Voltage Cable
INSTALLATION Return To Contents Pneumatic High Voltage On Output 6. If an insulating sheathing is used around the cable, it MUST Solenoid SOL1 turns on whenever high voltage (CR2) is on, be of a non-absorbent material, such as polyethelyne, and thereby passing air from its input to its output. -
Page 26: Motor Control Board Configuration
INSTALLATION Return To Contents Figure 8: High Voltage Connections SW1 KV ANALOG OUTPUT JUMPER POSITIONS 4-20 mA SELECT 0-10V SELECT (DEFAULT) F SCALE OV ADJ TP10 Ransburg ASSY / LECU4013 - REG2 REG1 Figure 9: Motor Control Board Configuration CP-02-02-R7 (10/2022) 26 / 47 www.carlisleft.com... -
Page 27: Master Control Board Configuration
INSTALLATION Return To Contents Figure 10: Master Control Board Configuration www.carlisleft.com 27 / 47 CP-02-02-R7 (10/2022) -
Page 28: Operation
OPERATION Return To Contents OPERATION HIGH VOLTAGE OFF CONTROL Reference the control panel schematic in Figure 5, the power supply schematic in Figure 14 and any system installation SEQUENCE drawings. When the front panel HV ON/OFF/RESET, external push- The following explanations assume that all external interlocks button, external interlock, or external PLC HV OFF opens or jumpers are installed and that the power supply is operat- the circuit to wire #10, voltage is removed from the coil of... -
Page 29: Master Control Board Functions
OPERATION Return To Contents Figure 11: Motherboard PCB MASTER CONTROL BOARD 5. Compares the overload setting with the actual high voltage output current and generates a latched overload FUNCTIONS condition that results in high voltage shutdown. A factory set potentiometer is located on the board that fine tunes A general description of the Master Control Board operation the overload trip point. -
Page 30: Motor Control Board
OPERATION Return To Contents MOTOR CONTROL BOARD is activated only on the HV ON command signal and not at the point where VAT1 starts from the “home” position. Therefore, if a HV ON command is given BEFORE VAT1 The LECU4013-00 Motor Control PC Board Assembly has had a chance to reach “home”... -
Page 31: Front Panel Controls And Indicators
OPERATION Return To Contents FRONT PANEL CONTROLS AND KV ON, OFF/RESET Switch INDICATORS This is a three position, spring return switch for manually turning high voltage on and off. The OFF position is also used to reset the power supply in the event of an overload Digital Displays alarm condition. -
Page 32: Leps5001 High Voltage Power Supply
OPERATION Return To Contents Figure 13: Front Panel Controls and Indicators LEPS5001 HIGH VOLTAGE POWER SUPPLY High voltage from the doubling circuit is connected to an output series resistor, R2, as protection against output tran- 0-120 VAC is supplied to power supply terminals, wires #1 sients. -
Page 33: Overload Adjustment Procedures
OPERATION Return To Contents Figure 14: Power Supply Schematic OVERLOAD ADJUSTMENT PROCEDURES Procedure for Unlisted Systems The overload adjustment is not as critical for FM listed sys- The following presumes that all components of the system tems such as the Aerobell 33 or REA- III atomizers since have been correctly installed and checked. - Page 34 OPERATION Return To Contents 9. Turn HV off by rotating the HV ON/OFF switch to the WARNING HV OFF position. † Since most coating materials are flammable and 10. If the actual output current was below approximately the possibility of arcing may exist during this adjust- 400 microamps, move the CURRENT OVERLOAD ment procedure, DO NOT trigger the fluid on during RANGE switch to the LOW position.
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Page 35: Maintenance
MAINTENANCE Return To Contents MAINTENANCE 2. Plug all unused access holes into the control panel in WARNING order to keep contamination out. † Electrical shock hazard. ALWAYS turn power OFF 3. Use the following guidelines for cleaning the Control prior to cleaning or servicing any part of the system. Panel and Power Supply tank. -
Page 36: Overload Procedures
MAINTENANCE Return To Contents TROUBLESHOOTING OVERLOAD PROCEDURE Periodically check for proper operation of the overload circuit WARNING as follows: 1. Turn ON high voltage to the applicator. † Field repair troubleshooting Voltage Master 2 system may require exposure to potentials that can cause SERIOUS BODILY WARNING INJURY or DEATH if proper procedures are not followed. - Page 37 MAINTENANCE Return To Contents Basic System Troubleshooting 2. Turn high voltage ON while the high voltage cables are When tracing problems, refer to the control panel schematic still disconnected. If there is still a problem with high in Figure 5, the Troubleshooting Guide in this section, the voltage or overloads then refer to the troubleshooting “Operation”...
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Page 38: Troubleshooting Guide
MAINTENANCE Return To Contents TROUBLESHOOTING GUIDE General Problem Procedure Solution Activate HV ON. Check for Check wires and wire connections from the power The High Voltage (kV) approximately 120VAC from terminal supply terminals to the external HV ON control de- Will Not Turn On TB2 #5 to TB2 chassis ground. - Page 39 MAINTENANCE Return To Contents TROUBLESHOOTING GUIDE (Cont.) General Problem Procedure Solution This symptom is most likely NOT a prob- Perform system inspection, cleaning, and diagnosis. Random Overloads lem with the power supply. Inspect and diagnose the entire system first. Refer to the common problems list at the be- ginning of this "Troubleshooting"...
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Page 40: Parts Identification
PARTS IDENTIFICATION Return To Contents PARTS IDENTIFICATION Figure 15: Control Panel Parts List - Front View CP-02-02-R7 (10/2022) 40 / 47 www.carlisleft.com... -
Page 41: Control Panel Parts List - Inside Door View
PARTS IDENTIFICATION Return To Contents Figure 16: Control Panel Parts List - Inside Door View www.carlisleft.com 41 / 47 CP-02-02-R7 (10/2022) -
Page 42: Control Panel Parts List - Inside View
PARTS IDENTIFICATION Return To Contents Figure 17: Control Panel Parts List - Inside View CP-02-02-R7 (10/2022) 42 / 47 www.carlisleft.com... -
Page 43: 78789 Control Panel Parts List
PARTS IDENTIFICATION Return To Contents 78789 CONTROL PANEL - PARTS LIST (Figure’s 15, 16, and 17) Description Item # Part # Notation 78820-00 Digital Panel Meter Assembly 76960-02 Pilot Light Lens, Yellow 76960-01 Pilot Light Lens, Red LSME0023 Alarm Horn HORN SSH-409 Knob... -
Page 44: Power Supply / Parts List
PARTS IDENTIFICATION Return To Contents Figure 18: Power Supply Parts List CP-02-02-R7 (10/2022) 44 / 47 www.carlisleft.com... -
Page 45: Recommended Spare Parts List
PARTS IDENTIFICATION Return To Contents LEPS5001 POWER SUPPLY - PARTS LIST (Figure 18) Description Item # Part # Notation A11385-00 Ground Wire Assembly Kit A11352-00 Cable Assembly LKIT0003-00 Connection Kit (Includes Items 5 thru 8) 18566-05 Transient Suppressor, 10 VDC LSMM0006 Rubber Bushing, Tapered 7296-00... -
Page 46: Manual Change Summary
MANUAL CHANGES Return To Contents MANUAL CHANGE SUMMARY CP-02-02-R7 - Replaces CP-02-02-R6 with the folowing changes: Change Description Page(s) Update to current manual design Update second label Add ground symbol to drawing Remove ITW Ransburg from figure 11 drawing Remove FM logo from drawing Remove FM logo from drawing CP-02-02-R7 (10/2022) 46 / 47... - Page 47 WARRANTY POLICY This product is covered by Carlisle Fluid Technologies’ materials and workmanship limited warranty. The use of any parts or accessories, from a source other than Carlisle Fluid Technologies, will void all warranties. Failure to reasonably follow any maintenance guidance provided, may invalidate any warranty.
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