CONTROL PANEL MODEL: 78789
POWER SUPPLY MODEL: LEPS5001
IMPORTANT: Before using this equipment,
carefully read SAFETY PRECAUTIONS, starting
on page 1, and all instructions in this manual.
Keep this Service Manual for future reference.
Service Manual Price: €25.00 (Euro)
$30.00 (U.S.)
Ransburg
NOTE: This manual has been changed from revision CP-02-02.5 to revision CP-02-02.6.
Reasons for this change are noted under “Manual Change Summary” inside the back
cover of this manual.
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read and
understand all of the technical and safety literature for your Ransburg 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.
W A R N I N G
!
The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identied.
This manual MUST be read and thor-
oughly 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 SAFETY STANDARD, LATEST EDITION, prior
to installing, operating, and/or servicing this
equipment.
W A R N I N G
!
While this manual lists standard specications
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 appropriate Ransburg equipment manuals to reconcile such differences.
Careful study and continued use of this manual will
provide a better understanding of the equipment
and process, resulting in more efcient operation,
longer trouble-free service and faster, easier
troubleshooting. If you do not have the manuals
and safety literature for your Ransburg system,
contact your local Ransburg representative or
Ransburg.
The hazards shown on the following pag-
es may occur during the normal use of this
equipment. Please read the hazard chart beginning on page 2.
1
CP-02-02.6
Ransburg
Voltage Master 2 - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
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.
SAFEGUARDS
Tells how to avoid the hazard.
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.
When using solvents for cleaning:
• Those used for equipment ushing should
have ash points equal to or higher than
those of the coating material.
• Those used for general cleaning must have
ash points above 100°F (37.8°C).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, 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 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 unautho-
rized equipment modications 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.
Never use equipment intended for use in waterborne installations to spray solvent based materials.
The paint process and equipment should be
set up and operated in accordance with NFPA33, NEC, OSHA, local, country, and European
Health and Safety Norms.
CP-02-02.6
2
Voltage Master 2 - Safety
Ransburg
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Explosion Hazard
Improper or inadequate operation and maintenance proce-
dures will cause a re hazard.
Protection against inadvertent
arcing that is capable of caus-
ing 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.
SAFEGUARDS
Tells how to avoid the 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 for every 10KV of output voltage
is required at all times.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2
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.
General Use and
Maintenance
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
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 50176.
Have re extinguishing equipment readily available and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
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 maintenance, and housekeeping. Reference OSHA, NFPA-33, EN Norms
and your insurance company requirements.
3
CP-02-02.6
Ransburg
Voltage Master 2 - Safety
AREA
Tells where hazards
may occur.
Spray Area /
High Voltage
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
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.
SAFEGUARDS
Tells how to avoid the hazard.
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.)
Operators must be grounded. Rubber soled insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator via conductive gloves or gloves with the
palm section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY 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.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33.
CP-02-02.6
4
Voltage Master 2 - Safety
Ransburg
AREA
Tells where hazards
may occur.
Electrical
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
High voltage equipment is utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may oc-
cur. 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 shutdown indicates a problem in the
system which requires correction.
An electrical arc can ignite coat-
ing materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specically approved for use in hazardous locations, the power supply, control cabinet,
and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas in accordance with NFPA-33 and EN
50176.
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.
Toxic Substances
Spray Area
Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Explosion Hazard –
Incompatible Materials
Halogenated hydrocarbon sol-
vents 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.
Follow the requirements of the Material Safety
Data Sheet supplied by coating material manufacturer.
Adequate exhaust must be provided to keep the
air free of accumulations of toxic materials.
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.
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.
5
CP-02-02.6
Ransburg
Voltage Master 2 - Atex
EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6
The following instructions apply to equipment
covered by certicate 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 certied 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 Identication
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 certication 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
specic chemicals.
Refer to "Specications" 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 certication 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.
CP-02-02.6
6
Voltage Master 2 - Atex
Ransburg
Voltage Master 2 High Voltage
Power Supply System ATEX
Product Marking Denitions
Ex Certicate Number: Sira 08ATEX5040X
Sira = Notied Body performing EC-type exam-
ination
08 = Year of certication
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
Product Marking
II 2 G
Ex = Specic marking of explosive protection
II = Equipment Group hazardous area charac-teristics
2 = Equipment Category
G = Type of explosive atmosphere (gases, vapors,
or mists)
Label 78789
Label LEPS5001
EEx 0.24mJ = The 78789 and LEPS5001 Pow-
er 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.
7
CP-02-02.6
Ransburg
INTRODUCTION
Voltage Master 2 - 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 applications. 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 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
transformer, 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.
(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, includ-
ing classied areas. (Contact 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 sufcient 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
• 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
CP-02-02.6
8
Voltage Master 2 - Introduction
Ransburg
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.
SPECIFICATIONS
Environmental / Physical
Operating Temperature: 0°C to 45°C
Storage Temperature: -40°C to 85°C
Humidity: 85% non-condensing
CONTROL PANEL
Electrical
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
* Not Listed With Factory Mutual
AC Output: 0-120 Volts AC at 4 Amps max.
(To Power Supply)
Dry Contacts: 10A, 1/3HP, 120VAC max.
Analog 0-10 Volts DC or 4-20ma
Inputs: (Jumper Selectable)
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)
Analog 0-10 Volts DC or 4-20ma
Outputs: (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
9
CP-02-02.6
Ransburg
Voltage Master 2 - Introduction
ELECTRICAL NOISE
Electrical noise refers to stray electrical signals
in the atmosphere 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.
pump control, 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 (analogkV
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 Electromagnetic 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.
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
pos-sible. 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 tha all AC I/O (interlocks, DC
CP-02-02.6
10
Voltage Master 2 - Introduction
Ransburg
11
Figure 1: Cable Connection Examples
CP-02-02.6
Ransburg
INSTALLATION
Voltage Master 2 - Installation
CP-02-02.6
Figure 2: Block Diagram Of A Typical Rea Iii Automatic Applicator Installation
12
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