Ransburg LEPS5001 User Manual

Ransburg
POWER SUPPLY SYSTEM
SERVICE MANUAL
CP-02-02.6
(Replaces CP-02-02.5) March - 2013
VOLTAGE MASTER
HIGH VOLTAGE
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.
Voltage Master 2 - Contents
CP-02-02.6
Voltage Master 2 - Contents
CONTENTS
SAFETY:
Ransburg
PAGE
1-6
SAFETY PRECAUTIONS.........................................................................................................
HAZARDS / SAFEGUARDS.....................................................................................................
ATEX:
EUROPEAN ATEX DIRECTIVE...............................................................................................
EUROPEAN ATEX LABELS.....................................................................................................
INTRODUCTION:
GENERAL DESCRIPTION.......................................................................................................
SPECIFICATIONS.....................................................................................................................
ELECTRICAL NOISE................................................................................................................
CABLE CONNECTION EXAMPLES........................................................................................
INSTALLATION:
BLOCK DIAGRAM OF TYPICAL REA III AUTOMATIC
APPLICATOR INSTALLATION.................................................................................................
BLOCK DIAGRAM OF TYPICAL AEROBELL 33
INSTALLATION..........................................................................................................................
LOCATION.................................................................................................................................
SAFETY GROUND....................................................................................................................
INPUT POWER..........................................................................................................................
SYSTEM INSTALLATION..........................................................................................................
78789-XX CONTROL PANEL SCHEMATIC............................................................................
POWER SUPPLY CONNECTIONS.........................................................................................
INTERLOCK CONNECTIONS..................................................................................................
AC REMOTE I/O........................................................................................................................
DC PUMP I/O.............................................................................................................................
DC REMOTE I/O........................................................................................................................
PNEUMATIC CONNECTIONS.................................................................................................
HIGH VOLTAGE CABLE...........................................................................................................
MOTOR CONTROL BOARD CONFIGURATION....................................................................
MASTER CONTROL BOARD CONFIGURATION..................................................................
1 2-5
6-7
6 7
8-11
8-9 9 10 11
12-23
12
13 14 14 14-15 15 16 17 17-18 19 19 19-20 21 21-22 23 23
OPERATION:
HIGH VOLTAGE ON CONTROL SEQUENCE........................................................................
HIGH VOLTAGE OFF CONTROL SEQUENCE......................................................................
OVERLOAD SEQUENCE.........................................................................................................
MOTHER BOARD FUNCTIONS...............................................................................................
MASTER CONTROL BOARD FUNCTIONS............................................................................
FRONT PANEL BOARD FUNCTIONS.....................................................................................
MOTOR CONTROL BOARD....................................................................................................
(Continued On Next Page)
24-32
24 24 24 25 26 26 26
CP-02-02.6
Ransburg
CONTENTS (Cont.)
OPERATION (Cont.):
Voltage Master 2 - Contents
PAGE 24-32
FRONT PANEL BOARD FUNCTIONS.....................................................................................
MOTOR CONTROL BOARD....................................................................................................
FRONT PANEL BOARD............................................................................................................
FRONT PANEL CONTROLS AND INDICATORS...................................................................
LEPS5001 HIGH VOLTAGE POWER SUPPLY.......................................................................
OVERLOAD ADJUSTMENT PROCEDURES.........................................................................
MAINTENANCE:
GENERAL..................................................................................................................................
OVERLOAD PROCEDURE......................................................................................................
TROUBLESHOOTING..............................................................................................................
TROUBLESHOOTING GUIDE.................................................................................................
PARTS IDENTIFICATION:
CONTROL PANEL PARTS LIST - FRONT VIEW...................................................................
CONTROL PANEL PARTS LIST - INSIDE DOOR VIEW.......................................................
CONTROL PANEL PARTS LIST - INSIDE VIEW....................................................................
78789 CONTROL PANEL PARTS LIST...................................................................................
POWER SUPPLY / PARTS LIST..............................................................................................
RECOMMENDED SPARE PARTS LIST..................................................................................
26 26 27 28-29 30 31-32
33-38
33-34 34 35-36 37-38
39-44
39 40 41 42 43-44 44
WARRANTY POLICIES:
LIMITED WARRANTY...............................................................................................................
45
45
CP-02-02.6
Voltage Master 2 - Safety
SAFETY
Ransburg
SAFETY PRECAUTIONS
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 identied.
 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 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 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 efcient 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 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.
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 specically 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 specically 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 specically 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 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.
CP-02-02.6
6
Voltage Master 2 - Atex
Ransburg
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 exam-
ination
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
Product Marking
II 2 G
Ex = Specic 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 classied 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 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
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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