Carlisle Ransburg 78789 User manual

EN
SERVICE MANUAL
CP-02-02-R8 (03/2023) 1 / 44 www.carlisleft.com
Voltage Master 2 High Voltage
Power Supply System
Control Panel Model: 78789
Power Supply Model: LEPS5001 or LEPS5002
(When used with AeroBell 33)

MANUAL CHANGES EN
CP-02-02-R8 (03/2023) 2 / 44 www.carlisleft.com
NOTE: ThismanualhasbeenchangedfromrevisionCP-02-02-R7torevision
CP-02-02-R8. Reasons for this change are noted under “Manual
Change Summary” inside the back cover of this manual.

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CONTENTS
EN
CONTENTS
(Continued On Next Page)
SAFETY: 5-9
Safety Precautions ............................................................................................................................................5
Hazards / Safeguards ........................................................................................................................................6
INTRODUCTION: 10-13
General Description ........................................................................................................................................10
 Specications .................................................................................................................................................11
Electrical Noise ............................................................................................................................................... 12
Cable Connection Examples .............................................................................................................................13
INSTALLATION: 14-24
Block Diagram of Typical Areobell 33 Installation................................................................................................14
Location .........................................................................................................................................................15
Safety Ground ................................................................................................................................................15
Input Power ...................................................................................................................................................15
System Installation .........................................................................................................................................16
78789-XX Control Panel Schematic ...................................................................................................................17
Power Supply Connections ..............................................................................................................................18
Interlock Connections .....................................................................................................................................18
AC Remote I/O ...............................................................................................................................................20
DC Pump I/O .................................................................................................................................................20
DC Remote I/O ...............................................................................................................................................20
Pneumatic Connections ...................................................................................................................................21
High Voltage Cable .........................................................................................................................................22
 MotorControlBoardConguration ...................................................................................................................23
 MasterControlBoardConguration..................................................................................................................24
OPERATION: 25-31
High Voltage ON Control Sequence .................................................................................................................. 25
High Voltage OFF Control Sequence ................................................................................................................. 25
Overload Sequence .........................................................................................................................................25
Mother Board Functions .................................................................................................................................. 25
Master Control Board Functions .......................................................................................................................26
Front Panel Board Functions ............................................................................................................................ 26
Motor Control Board ....................................................................................................................................... 27
Front Panel Board ...........................................................................................................................................27
Front Panel Controls and Indicators ..................................................................................................................28
LEPS5001 High Voltage Power Supply ..............................................................................................................29
Overload Adjustment Procedures .....................................................................................................................30
CONTENTS
(Continued On Next Page)
SAFETY: 5-9
Safety Precautions ............................................................................................................................................5
Hazards / Safeguards ........................................................................................................................................6
INTRODUCTION: 10-13
General Description ........................................................................................................................................10
Specications .................................................................................................................................................11
Electrical Noise ............................................................................................................................................... 12
Cable Connection Examples .............................................................................................................................13
INSTALLATION: 14-24
Block Diagram of Typical Areobell 33 Installation................................................................................................14
Location .........................................................................................................................................................15
Safety Ground ................................................................................................................................................15
Input Power ...................................................................................................................................................15
System Installation .........................................................................................................................................16
78789-XX Control Panel Schematic ...................................................................................................................17
Power Supply Connections ..............................................................................................................................18
Interlock Connections .....................................................................................................................................18
AC Remote I/O ...............................................................................................................................................20
DC Pump I/O .................................................................................................................................................20
DC Remote I/O ...............................................................................................................................................20
Pneumatic Connections ...................................................................................................................................21
High Voltage Cable .........................................................................................................................................22
MotorControlBoardConguration ...................................................................................................................23
MasterControlBoardConguration ..................................................................................................................24
OPERATION: 25-31
High Voltage ON Control Sequence .................................................................................................................. 25
High Voltage OFF Control Sequence ................................................................................................................. 25
Overload Sequence .........................................................................................................................................25
Mother Board Functions .................................................................................................................................. 25
Master Control Board Functions .......................................................................................................................26
Front Panel Board Functions ............................................................................................................................ 26
Motor Control Board ....................................................................................................................................... 27
Front Panel Board ...........................................................................................................................................27
Front Panel Controls and Indicators ..................................................................................................................28
LEPS5001 High Voltage Power Supply ..............................................................................................................29
Overload Adjustment Procedures .....................................................................................................................30

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CONTENTS EN
CONTENTS(Cont.)
MAINTENANCE: 32-36
General ..........................................................................................................................................................32
Overload Procedures ....................................................................................................................................... 33
Troubleshooting ..............................................................................................................................................33
Troubleshooting Guide ....................................................................................................................................35
PARTS IDENTIFICATION: 37-42
Control Panel Parts List - Front View ................................................................................................................ 37
Control Panel Parts List - Inside Door View........................................................................................................ 38
Control Panel Parts List - Inside View............................................................................................................... 39
78789 Control Panel Parts List ......................................................................................................................... 40
Power Supply / Parts List ................................................................................................................................. 41
Recommended Spare Parts List ........................................................................................................................42
MANUAL CHANGE SUMMARY: 43
Manual Changes .............................................................................................................................................43
CONTENTS(Cont.)
MAINTENANCE: 32-36
General ..........................................................................................................................................................32
Overload Procedures ....................................................................................................................................... 33
Troubleshooting ..............................................................................................................................................33
Troubleshooting Guide ....................................................................................................................................35
PARTS IDENTIFICATION: 37-42
Control Panel Parts List - Front View ................................................................................................................ 36
Control Panel Parts List - Inside Door View........................................................................................................ 38
Control Panel Parts List - Inside View............................................................................................................... 39
78789 Control Panel Parts List ......................................................................................................................... 40
Power Supply / Parts List ................................................................................................................................. 41
Recommended Spare Parts List ........................................................................................................................42
MANUAL CHANGE SUMMARY: 43
Manual Changes .............................................................................................................................................43

SAFETY
EN
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WARNING
!
WARNING
!
WARNING
!
CAUTION
!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any electrostatic
coating system , read and understand all of the technical
and safety literature for your products. This manual contains
informationthatisimportantforyoutoknowandunderstand.
ThisinformationrelatestoUSERSAFETYandPREVENTING
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 specifications and
service procedures, some minor deviations may be found
between this literature and your equipment. Dierences
in local codes and plant requirements, material delivery
requirements, etc., make such variations inevitable.
Comparethismanualwithyoursysteminstallationdrawings
and associated equipment manuals to reconcile such
d i  e r e n c e s . 
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 16985
SAFETY STANDARDS, LATEST EDITION, or
applicable country safety standards, prior to installing,
operating, and/or servicing this equipment.
SAFETY
Repairs may only be performed by personnel authorized by
Carlisle Fluid Technologies.
Careful study and continued use of this manual will provide a
betterunderstandingoftheequipmentandprocess,resulting
inmoreecientoperation,longertrouble-freeserviceand
faster,easiertroubleshooting. Ifyoudonothavethemanuals
and safety literature for your equipment, contact your local
Carlisle Fluid Technologies representative or Carlisle Fluid
Technologies technical support.
The hazards shown on the following pages may
occur during the normal use of this equipment.
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SAFETY EN
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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
opriortocleaning,ushing,ormaintenance.
Spray booth ventilation must be kept at the rates
required by NFPA 33, EN 16985, 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 (25mm)
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
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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.
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 mainte-
nance, and housekeeping. Reference OSHA, NFPA 33, EN
Norms and your insurance company requirements.
General Use
and Mainte-
nance
Spray Area Explosion Hazard
Electrostatic arcing must be prevented. Safe sparking
distance must be maintained between the parts being
coated and the applicator. A distance of 1 inch (25mm) 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 or applicable
county code hazardous areas, in accordance with NFPA 33.
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o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 16985.
Have re extinguishing equipment readily available and
tested periodically.
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SAFETY EN
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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.
Electrical Discharge
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 16985.)
Operators must be grounded. Grounding straps on wrists or
legs may be used to assure adequate ground contact.
Footware to be used by operator shall comply with EN ISO 20344,
resistance not to exceed 100 Meg Ohm. Protective clothing
including gloves should comply with EN 1149-5, resistance not to
exceed 100 Meg Ohm.
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 16985 OR SPECIFIC COUNTRY
SAFETY CODES REGARDING PROPER OPERATOR GROUND-
ING.
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othepowersupplypriortoushing,cleaning,or
working on spray system equipment or applicable county code.
Unless specically approved for use in hazardous locations,
all electrical equipment must be located outside or applicable
country code, hazardous areas, in accordance with NFPA 33.
Avoidinstallinganapplicatorintoauidsystemwherethe
solvent supply is ungrounded.
Do not touch the applicator electrode while it is energized.
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SAFETY
EN
CP-02-02-R8 (03/2023)9 / 44www.carlisleft.com
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.
Electrical Discharge
Electrical
Equipment
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. Reference EN 12215 or
applicable code.
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 Certain materials may be
harmful if inhaled, or if there
is contact with the skin.
Unlessspecicallyapprovedforuseinhazardouslocations,
the power supply, control cabinet, and all other electrical
equipment must be located outside or applicable country
codes, hazardous areas in accordance with NFPA 33 and
EN 16985.
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.
Spray applicators require that aluminum inlet ttings be
replaced with stainless steel.
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators, triggering
valves, etc. Halogenated hydrocarbon solvents must
never be used with aluminum equipment during spraying,
ushing,orcleaning.Readthelabelordatasheetforthe
material you intend to spray. If in doubt as to whether or
not a coating or cleaning material is compatible, contact
your coating supplier. Any other type of solvent may be
used with aluminum equipment.
Halogenated hydrocarbon solvents
for example: methylene chloride
and 1,1,1, - Trichloroethane are
not chemically compatible with the
aluminum that might be used in
many system components. The
chemical reaction caused by these
solvents reacting with aluminum
can become violent and lead to an
equipment explosion.
Explosion Hazard —
Incompatible Materials
Spray Area
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INTRODUCTION EN
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INTRODUCTION
GENERAL DESCRIPTION
The Voltage Master 2 high voltage power supply system
includesacontrolpanelandpowersupplyunitincombination
to produce up to 100kV DC continuous operating voltage
while delivering up to 1,500 microamps load current. This
heavy duty, high power system provides for rugged and
reliableoperationinavarietyofindustrialnishingappli-
cations. The Voltage Master 2 system also includes the
necessary system interfaces for complete remote control
and monitoring functions.
Voltage Master 2 systems can include, but are not limited
to, the following:
• Power Supply Control Panel
The control panel contains all of the necessary control
circuitry, operator interface controls and remote I/O in-
terfaces. A single cable connects the control panel to the
power supply unit.
• LEPS5001 HV Power Supply Tank
The power supply tank contains the high voltage trans-
former, voltage multiplier, and other components necessary
to generate a high voltage output and to return actual
voltage and current feedback signals to the control panel.
All components of the power supply were design selected
for reliable, heavy duty service. The components, including
the high voltage transformer, operate immersed in high
quality (non-pcb) dielectric oil for electrical insulation and
to provide heat dissipation. The power supply is supplied
as a separate unit in order that it can be installed as close
to the applicators as possible. This minimizes the amount
of high voltage cable and routing hardware, resulting in
improved system safety and reliability.
• HV Junction Tanks
Highvoltagejunction tanks receive an input fromthe power
supply, split the input, and provide multiple outputs. Each
junction tank output can be connected to a single applicator
or station of applicators. The internal components of the
each junction tank are immersed in high quality (non-pcb)
dielectric oil. Consult the appropriate junction tank service
manual or your authorized Ransburg representative for
further information.
• HV Cable
The Ransburg high voltage cable is specially formulated and
constructedtooeramaximumlevelofdielectricprotection
while maintaining a small diameter and bending radius for
easy routing.
• Remote Pneumatic ON/OFF Switch Station
This is provided to serve as a simple, industrial ON/OFF
control that can be located at the system operator stations
inaconvenientlocation,includingclassiedareas.(Contact
yourRansburgrepresentativeor Ransburgcustomerservice
for details.)
• Air Logic Stations
These standard system panels include all of the necessary
controls for disk or bell system integration. (Contact your
Ransburg representative or Ransburg customer service for
details.)
The Voltage Master 2 system supplies a high degree of
safety by continuously monitoring the output current and
rapidly de-energizing highvoltage in the event that the user
selected maximum output current level (overload setting) is
exceeded.Thesafetycircuitissucienttoeliminatemost
possiblearcingconditions,however,theoverloadcurrent
settingmustbeproperlysetasdescribedin"Overload
Adjustment Procedures" in the "Operation" section
of this manual, to ensure safe operation.
The Voltage Master 2 system, with control panel 78789-
02, is listed by Factory Mutual for use with Aerobell 33 and
REA-III automatic systems. Additional features, described
later in this manual, include remote analog control of the
high voltage and overload setpoints. Analog output signals
are also supplied for remote monitoring of the actual high
voltage and current outputs.
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