Carlisle Ransburg LEPS5001 User manual

EN
SERVICE MANUAL
CP-02-02-R7 (10/2022) 1 / 47 www.carlisleft.com
Voltage Master 2 High Voltage
Power Supply System
Control Panel Model: 78789
Power Supply Model: LEPS5001

MANUAL CHANGES EN
CP-02-02-R7 (10/2022) 2 / 47 www.carlisleft.com
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)3 / 47www.carlisleft.com
CONTENTS
EN
CONTENTS
(Continued On Next Page)
SAFETY: 5-9
Safety Precautions ........................................................................................................................................................5
Hazards / Safeguards ....................................................................................................................................................6
ATEX: 10-11
European ATEX Directive ............................................................................................................................................10
European ATEX Labels ...............................................................................................................................................11
INTRODUCTION: 12-15
General Description .....................................................................................................................................................12
Specications ..............................................................................................................................................................13
Electrical Noise ............................................................................................................................................................14
Cable Connection Examples .......................................................................................................................................15
INSTALLATION: 16-27
Block Diagram of Typical REA III Automatic Applicator Installation............................................................................. 16
Block Diagram of Typical Areobell 33 Installation........................................................................................................ 17
Location ...................................................................................................................................................................... 18
Safety Ground ............................................................................................................................................................ 18
Input Power ................................................................................................................................................................ 18
System Installation ..................................................................................................................................................... 19
78789-XX Control Panel Schematic ........................................................................................................................... 20
Power Supply Connections ........................................................................................................................................ 21
Interlock Connections ................................................................................................................................................. 21
AC Remote I/O ........................................................................................................................................................... 23
DC Pump I/O .............................................................................................................................................................. 23
DC Remote I/O ........................................................................................................................................................... 23
Pneumatic Connections ............................................................................................................................................. 24
High Voltage Cable ..................................................................................................................................................... 25
Motor Control Board Conguration ............................................................................................................................. 26
Master Control Board Conguration ........................................................................................................................... 27
OPERATION: 28-34
High Voltage ON Control Sequence ............................................................................................................................28
High Voltage OFF Control Sequence ..........................................................................................................................28
Overload Sequence .....................................................................................................................................................28
Mother Board Functions ..............................................................................................................................................28
Master Control Board Functions ..................................................................................................................................29
Front Panel Board Functions .......................................................................................................................................29
Motor Control Board ....................................................................................................................................................30
Front Panel Board .......................................................................................................................................................30
Front Panel Controls and Indicators ............................................................................................................................31
LEPS5001 High Voltage Power Supply .......................................................................................................................32
Overload Adjustment Procedures ................................................................................................................................33

CP-02-02-R7 (10/2022) 4 / 47 www.carlisleft.com
CONTENTS EN
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
Power Supply / Parts List ............................................................................................................................................44
Recommended Spare Parts List .................................................................................................................................45
MANUAL CHANGE SUMMARY: 46
Manual Changes .........................................................................................................................................................46

SAFETY
EN
CP-02-02-R7 (10/2022)5 / 47www.carlisleft.com
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
information that is important for you to know and understand.
This information relates to USER SAFETY and PREVENTING
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 specications and service
procedures, some minor deviations may be found between
this literature and your equipment. Differences in local codes
and plant requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this manual with
your system installation drawings and associated equipment
manuals to reconcile such differences.
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
better understanding of the equipment and process, resulting
in more efcient operation, longer trouble-free service and
faster, easier troubleshooting. If you do not have the manuals
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.
Return To Contents

SAFETY EN
CP-02-02-R7 (10/2022) 6 / 47 www.carlisleft.com
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 off
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.
Return To Contents

SAFETY
EN
CP-02-02-R7 (10/2022)7 / 47www.carlisleft.com
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
Maintenance
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 off 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.
Return To Contents

SAFETY EN
CP-02-02-R7 (10/2022) 8 / 47 www.carlisleft.com
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 COUN-
TRY SAFETY CODES REGARDING PROPER OPERATOR
GROUNDING.
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 off 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.
Return To Contents

SAFETY
EN
CP-02-02-R7 (10/2022)9 / 47www.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
Return To Contents

ATEX EN
CP-02-02-R7 (10/2022) 10 / 47 www.carlisleft.com
ATEX
EUROPEAN ATEX DIRECTIVE
94/9/EC, ANNEX II, 1.0.6
The following instructions apply to equipment covered by
certicate number Sira 08ATEX5040X:
1. The equipment may be used with ammable gases and
vapors with apparatus groups II and with temperature
class T6.
2. The equipment is only certied for use in ambient
temperatures in the range +12.8°C to +40°C and should
not be used outside this range.
3. Installation shall be carried out by suitably trained
personnel in accordance with the applicable code of
practice e.g. EN 60079-14:1997.
4. Inspection and maintenance of this equipment shall be
carried out by suitably trained personnel in accordance
with the applicable code of practice e.g. EN 60079-17.
5. Repair of this equipment shall be carried out by suitable
trained personnel in accordance with the applicable code
of practice e.g. EN 60079-19.
6. Putting into service, use, assembling, and adjustment of
the equipment shall be tted by suitably trained personnel
in accordance with the manufacturer's documentation.
Refer to the "Table of Contents" of this service manual:
a. Installation
b. Operation
c. Maintenance
d. Parts Identication
7. Components to be incorporated into or used as
replacement parts of the equipment shall be tted
by suitably trained personnel in accordance with the
manufacturer's documentation.
8. The certication of this equipment relies upon the
following materials used in its construction:
If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility of
the user to take suitable precautions that prevent it from
being adversely affected, thus ensuring that the type of
protection provided by the equipment is not compromised.
Aggressive substances: e.g. acidic liquids or gases that
may attack metals, or solvents that may affect polymeric
materials.
Suitable precautions: e.g. regular checks as part of
routine inspections or establishing from the material's
data sheets that it is resistant to specic chemicals.
Refer to "Specications" in the "Introduction" section:
a. All uid passages contain stainless steel or
nylon ttings.
b. High voltage cascade is encapsulated with a
solvent resistant epoxy.
9. A recapitulation of the certication marking is detailed in
the "ATEX" section, on the next page, drawing numbers:
78886 and 78894-04.
10. The characteristics of the equipment shall be detailed
e.g. electrical, pressure, and voltage parameters.
The manufacturer should note that, on being put into
service, the equipment must be accompanied by
a translation of the instructions in the language or
languages of the country in which the equipment is to
be used and by the instructions in the original language.
Return To Contents

ATEX
EN
CP-02-02-R7 (10/2022)11 / 47www.carlisleft.com
Voltage Master 2 High Voltage Power Supply
System ATEX Product Marking Denitions
Ex Certicate Number: Sira 08ATEX5040X
Sira = Notied Body performing EC-type
examination
08 = Year of certication
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
Ex = Specic marking of explosive protection
II = Equipment Group hazardous area
characteristics
2 = Equipment Category
G = Type of explosive atmosphere (gases,
vapors, or mists)
EEx 0.24mJ = The 78789 and LEPS5001 Power Supplies
are suitable for use in electrostatic spraying installations
complying with EN 50050 as they are a Type A class with a
discharge energy limit of 0.24mJ.
Label 78789
Label LEPS5001
Product Marking
II 2 G
Return To Contents

INTRODUCTION EN
CP-02-02-R7 (10/2022) 12 / 47 www.carlisleft.com
INTRODUCTION
GENERAL DESCRIPTION
The Voltage Master 2 high voltage power supply system
includes a control panel and power supply unit in combination
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 cir-
cuitry, operator interface controls and remote I/O interfaces.
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 transform-
er, 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 pro-
vide 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
High voltage junction tanks receive an input from the 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 offer 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. (Con-
tact your Ransburg representative or Ransburg customer
service 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 high voltage in the event that the user
selected maximum output current level (overload setting) is
exceeded. The safety circuit is sufcient to eliminate most
possible arcing conditions, however, the overload current
setting must be properly set as described in "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.
Return To Contents

INTRODUCTION
EN
CP-02-02-R7 (10/2022)13 / 47www.carlisleft.com
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. (6.9 bar)
POWER SUPPLY
Size: 21" Dia. x 28" H (.53m Dia. x .71m H)
Weight: 254 lbs. (115.2 kg)
CONTROL PANEL
AC Input:
Model 78789-02 (Standard) 105-130 Volts AC 50/60 Hz, Single Phase, Fuse Protected at 5 Amps
Model 78789-04* 210-260 Volts AC, 50/60 Hz, Single Phase, Fuse Protected at 2.5 Amps
AC Output: 0-120 Volts AC at 4 Amps max. (To Power Supply)
Dry Contacts: 10A, 1/3HP, 120VAC max.
Analog Inputs: 0-10 Volts DC or 4-20ma (Jumper Selectable)
Analog Outputs: 0-10 Volts DC or 4-20ma (Jumper Selectable)
POWER SUPPLY
AC Input: 0-120 Volts AC at 4 Amps max (From Control Panel)
HV Output: 0 to negative 100kV DC
Current Output: 1,500 microamps max. at 100kV
Analog Outputs: 0-10 Volts DC
* Not Listed With Factory Mutual
Electrical
Return To Contents

INTRODUCTION EN
CP-02-02-R7 (10/2022) 14 / 47 www.carlisleft.com
ELECTRICAL NOISE
Electrical noise refers to stray electrical signals in the atmo-
sphere at various signal strengths and frequencies that can
affect the operation of equipment. One of the best ways to
prevent this is to shield the equipment and cables within a
continuous ground envelope, such that any incident noise
will be conducted to earth ground before it can affect the
circuit conductors.
For conductors inside the control panel and power supply
tank, the grounded enclosures provide this envelope. A
conductive gasket has been used on the control panel door
to ensure a continuous ground envelope between the door
and cabinet.
For the control cable that runs from the control panel to the
power supply tank, a shielded cable has been used. The
shield consists of an overall foil shield in combination with
an overall braided shield. This provides the most effective
shielding, as the foil covers the "holes" in the braid, and
the braid allows for practical 360° termination at both ends
of the cable.
The AC input cord is not shielded, but instead is directed
to an AC line lter as soon as it enters the cabinet. This
lter lters out any noise that comes in on the AC line. For
maximum noise immunity the AC line should connect to
the lter as soon as it enters the cabinet with as short of
leads as possible. Additional noise protection is provided
by running the AC input line to the control panel in grounded
conduit, which is the recommended method and is required
by most codes.
For maximum noise protection any user supplied input/
output (I/O) wiring should be made using shielded cable or
conduit which is connected to earth ground in a continuous
360° fashion at both ends. The best way to do this is to
use a connector/tting at each end of the cable/conduit that
makes contact to the grounded enclosure in this manner.
Connecting the drain wire of a shield to a ground point on
or in the cabinet (usually referred to as pigtailing) is not an
effective method of shielding and actually making things
worse (see Figure 1).
It is recommended that all AC I/O (interlocks, DC pump con-
trol, eternal HV ON/OFF, external alarm) be run in conduit.
If desired and codes permit, cabling may be used for these
signals, but for maximum noise immunity the cabling must
contain overall foil and braided shields and be terminated
as described in the previous paragraph.
Cable is recommended for the DC I/O (analog kV setpoint in,
overload current setpoint in, analog kV out, analog current
out). Again, for maximum noise immunity the cabling must
contain overall foil and braided shields and be terminated
in a continuous 360° manner as previously described.
Special ttings have been provided on the control panel for
termination of these cables where they enter the cabinet.
The use of these ttings is described under "DC Remote
I/O" in the "Installation" section of this manual. Using the
methods described above, the Voltage Master 2 has been
successfully tested to the stringent standards of the Elec-
tromagnetic Compatibility Directive of the European Union.
The results conclude that the Voltage Master 2 is neither
a source of electrical noise nor affected by electrical noise
when the previous methods are utilized.
Return To Contents

INTRODUCTION
EN
CP-02-02-R7 (10/2022)15 / 47www.carlisleft.com
Figure 1: Cable Connection Examples
Return To Contents

INSTALLATION EN
CP-02-02-R7 (10/2022) 16 / 47 www.carlisleft.com
INSTALLATION
Figure 2: Block Diagram Of A Typical Rea Iii Automatic Applicator Installation
Return To Contents

INSTALLATION
EN
CP-02-02-R7 (10/2022)17 / 47www.carlisleft.com
Figure 3: Block Diagram Of A Typical Aerobell 33 Installation
Return To Contents

INSTALLATION EN
CP-02-02-R7 (10/2022) 18 / 47 www.carlisleft.com
CAUTION
!
CAUTION
!
NOTE
WARNING
!
The 78789 control panel and the LEPS5001 power
supply MUST be located outside the hazardous area
(see NFPA-33).
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 requirements for
operating and servicing safely, are followed.
Install the control panel in a convenient area outside the
hazardous location, where it will be protected from the
possibility of any contact with water, vapor or high humidity,
and ambient temperatures in excess of 120oF. The area
should be clean, dry, and well ventilated.
Locate the power supply tank in a convenient area as close
to the applicator(s) as possible in order to minimize the
amount of high voltage cable required.
INPUT POWER
The AC Input power routing and connections to the control
panel should be supplied from a FUSED DISCONNECT and
should meet all applicable National Electrical Code (NEC)
guidelines and any other requirements as suitable for the
location. LOCKOUT/ TAGOUT procedures should be put
in place for the fused disconnect. Using conduit, route the
input power wiring through the AC power opening in the top
left corner of the control panel. For greatest noise immunity
theAC input should be located as close as possible to theAC
line lter (see Figure 4). For this reason, it is recommended
that the AC input not be relocated to another position on the
control panel. Route the input wiring through the conduit
and attach to terminal block TB7 as shown in Figure 4.
LOCATION
Do not locate the control panel or power supply
near or adjacent to heat producing equipment such as
ovens, high wattage lamps, steam pipes, etc.
SAFETY GROUND
Control Panel
Ground the control panel by mounting to structural steel that
is at earth ground potential. If this is not possible, ground
the control panel by connecting the supplied ground wire
assembly from the control panel ground stud to the nearest
true earth ground (structural steel, pipes, or driven ground
rod). For maximum protection from electrical noise make
this connection as short as possible.
Power Supply Tank
Ground the power supply tank by connecting the supplied
ground wire assembly from the power supply ground stud
to the nearest true earth ground (structural steel, pipes, or
driven ground rod). For maximum protection from electrical
noise make this connection as short as possible.
To shorten the ground wire assembly, use a
screwdriver to remove the lug (at end opposite clamp)
from the end of the assembly, cut the wire to the length
needed, strip insulation 1" from cut and reattach the lug.
Ensure that the control panel and power supply
tank are properly grounded to a true earth ground as
described above.
The use of a constant voltage transformer (CVT) is
recommended. This will improve high voltage regulation,
especially if there are large AC line voltage uctuations or
voltage transients such as those typically produced by heavy
electric machinery or welding equipment. CVT's are available
from local electrical suppliers and can be used between the
fused disconnect and the control panel. The CVT should
be rated for 750VA or greater and be properly rated for the
voltage and frequency of the source power supplied by the
fused disconnect.
Return To Contents

INSTALLATION
EN
CP-02-02-R7 (10/2022)19 / 47www.carlisleft.com
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.
Figure 4: AC Power Input Connections
Return To Contents

INSTALLATION EN
CP-02-02-R7 (10/2022) 20 / 47 www.carlisleft.com
Figure 5: 78789-Xx Control Panel Schematic
Return To Contents