Related Manuals for Carlisle Ransburg 78789
Summary of Contents for Carlisle Ransburg 78789
- Page 1 SERVICE MANUAL Voltage Master 2 High Voltage Power Supply System Control Panel Model: 78789 Power Supply Model: LEPS5001 or LEPS5002 (When used with AeroBell 33) CP-02-02-R8 (03/2023) 1 / 44 www.carlisleft.com...
- Page 2 MANUAL CHANGES NOTE: This manual has been changed from revision CP-02-02-R7 to revision CP-02-02-R8. Reasons for this change are noted under “Manual Change Summary” inside the back cover of this manual. CP-02-02-R8 (03/2023) 2 / 44 www.carlisleft.com...
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Page 3: Table Of Contents
CONTENTS CONTENTS CONTENTS SAFETY: SAFETY: Safety Precautions ............................5 Safety Precautions ............................5 Hazards / Safeguards ............................6 Hazards / Safeguards ............................6 INTRODUCTION: INTRODUCTION: 10-13 10-13 General Description ............................10 General Description ............................10 Specifications ..............................11 Specifications ..............................11 Electrical Noise ............................... - Page 4 CONTENTS CONTENTS CONTENTS (Cont.) (Cont.) MAINTENANCE: MAINTENANCE: 32-36 32-36 General ................................32 General ................................32 Overload Procedures ............................33 Overload Procedures ............................33 Troubleshooting .............................. 33 Troubleshooting .............................. 33 Troubleshooting Guide ............................ 35 Troubleshooting Guide ............................ 35 PARTS IDENTIFICATION: PARTS IDENTIFICATION: 37-42 37-42 Control Panel Parts List - Front View ........................
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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 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. Spray Area Explosion Hazard 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 combustible materials may occur.
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Page 10: 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 11: Specifications 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 12: Electrical Noise Electrical Noise
INTRODUCTION Return To Contents ELECTRICAL NOISE Electrical noise refers to stray electrical signals in the atmo- For maximum noise protection any user supplied input/ 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. One of the best ways to conduit which is connected to earth ground in a continuous prevent this is to shield the equipment and cables within a... -
Page 13: Cable Connection Examples Cable Connection Examples
INTRODUCTION Return To Contents Figure 1: Cable Connection Examples www.carlisleft.com 13 / 44 CP-02-02-R8 (03/2023) -
Page 14: Installation
INSTALLATION Return To Contents INSTALLATION Figure 3: Block Diagram Of A Typical Aerobell 33 Installation CP-02-02-R8 (03/2023) 14 / 44 www.carlisleft.com... -
Page 15: Location 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 16: System Installation 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 17: 78789-Xx Control Panel Schematic 78789-Xx Control Panel Schematic
INSTALLATION Return To Contents Figure 5: 78789-Xx Control Panel Schematic www.carlisleft.com 17 / 44 CP-02-02-R8 (03/2023) -
Page 18: Power Supply Connections 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 19 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 20: Ac Remote I/Oac 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 (AC) mote position and high voltage is enabled, a 0 to 10 VDC or opening in the bottom left corner of the control panel. -
Page 21: Pneumatic Connections 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 22: High Voltage Cable High Voltage Cable
INSTALLATION Return To Contents Pneumatic High Voltage On Output 6. If an insulating sheathing is used around the cable, it Solenoid SOL1 turns on whenever high voltage (CR2) is on, MUST be of a non-absorbent material, such as polyethe- thereby passing air from its input to its output. This out- lyne, and should be routed to prevent contact with, or put is most commonly used to connect to the high voltage entrapment of, solvents or cleaning solutions. -
Page 23: Motor Control Board Configuration Motor Control Board Configuration
INSTALLATION Return To Contents Figure 8: High Voltage Connections Figure 9: Motor Control Board Configuration www.carlisleft.com 23 / 44 CP-02-02-R8 (03/2023) -
Page 24: Master Control Board Configuration Master Control Board Configuration
INSTALLATION Return To Contents Figure 10: Master Control Board Configuration CP-02-02-R8 (03/2023) 24 / 44 www.carlisleft.com... -
Page 25: 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 inter- button, external interlock, or external PLC HV OFF opens locks or jumpers are installed and that the power supply the circuit to wire #10, voltage is removed from the coil of... -
Page 26: Master Control Board Functions 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 27: Motor Control Board Motor Control Board
OPERATION Return To Contents MOTOR CONTROL BOARD inhibit timer 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 The LECU4013-00 Motor Control PC Board Assembly receives VAT1 has had a chance to reach “home”... -
Page 28: Front Panel Controls And Indicators 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. The switch is illuminated red when high The KILOVOLTS and MICROAMPS meters are both 3-½... -
Page 29: Leps5001 High Voltage Power Supply 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 30: Overload Adjustment Procedures Overload Adjustment Procedures
OPERATION Return To Contents Figure 14: Power Supply Schematic OVERLOAD ADJUSTMENT PROCEDURES The overload circuit is still important, even if set to the least WARNING sensitive setting, in the event that a HV cable should fail or other electrical discharge should occur, or if the output †... - Page 31 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 RANGE ment procedure, DO NOT trigger the fluid on during switch to the LOW position.
- Page 32 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 33 MAINTENANCE Return To Contents TROUBLESHOOTING OVERLOAD PROCEDURE Periodically check for proper operation of the overload circuit WARNING as follows: † Field repair troubleshooting 1. Turn ON high voltage to the applicator. 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 34 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” section, and the “Parts Identification” section guide, otherwise, if the power supply now seems to be...
- Page 35 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 approximately 120VAC from terminal supply terminals to the external HV ON control (kV) Will Not Turn TB2 #5 to TB2 chassis ground.
- Page 36 MAINTENANCE Return To Contents TROUBLESHOOTING GUIDE (Cont.) General Problem Procedure Solution This symptom is most likely NOT a Perform system inspection, cleaning, and diagnosis. Random Overloads problem with the power supply. Inspect and diagnose the entire system first. Refer to the common problems list at the beginning of this "Troubleshooting"...
- Page 37 PARTS IDENTIFICATION Return To Contents PARTS IDENTIFICATION Figure 15: Control Panel Parts List - Front View www.carlisleft.com 37 / 44 CP-02-02-R8 (03/2023)
- Page 38 PARTS IDENTIFICATION Return To Contents Figure 16: Control Panel Parts List - Inside Door View CP-02-02-R8 (03/2023) 38 / 44 www.carlisleft.com...
- Page 39 PARTS IDENTIFICATION Return To Contents Figure 17: Control Panel Parts List - Inside View www.carlisleft.com 39 / 44 CP-02-02-R8 (03/2023)
- Page 40 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 41 PARTS IDENTIFICATION Return To Contents Figure 18: Power Supply Parts List www.carlisleft.com 41 / 44 CP-02-02-R8 (03/2023)
- Page 42 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 43 MANUAL CHANGES Return To Contents MANUAL CHANGE SUMMARY CP-02-02-R8 - Replaces CP-02-02-R7 with the folowing changes: Change Description Page(s) Remove CE logo from front page Remove ATEX section 10-11 www.carlisleft.com 43 / 44 CP-02-02-R8 (03/2023)
- Page 44 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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