LEPS5001 Power Supply (Serv. Man. CP-95-02.5)
Contents
1. 17 LEPS5001 POWER SUPPLY PARTS 18 WARRANTY POLICIES 19 LIMITED WARRANTY nen 19 APPENDIX 20 23 PAINT AND SOLVENT SPECIFICATIONS 20 VISCOSITY CONVERSION CHART t 21 22 VOLUMETRIC CONTENT OF HOSE OR 23 CP 95 02 5 LEPS5001 Power Supply Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety liter ature 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 informa tion 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 proce dure in progress While this manual lists standard specifications 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 Compare2. AlddNS M3MOd NO 31 201 SYOLOINNOD 318VO JOVIIOA GSCTSIHSNN ONIHSN I NYL M38OS ONINIVL38 LAN 40193NNOO D Figure 4 High Voltage Connections 12 CP 95 02 5 LEPS5001 Power Supply Operation Ransburg OPERATION THEORY OF OPERATION REFER TO FIGURE 3 0 to 120 VAC input is supplied to terminals TB2 4 and TB2 5 of the LEPS5001 Power Supply from the LECU5003 Control Panel Inside the LEPS5001 Power Supply this 0 to 120 VAC signal is supplied to the primary of high voltage transformer 2T In operation alternate halves of transformer 2T s high voltage secondary AC waveform charge capacitors C1 and C2 to the peak voltage of the secondary output Since the capacitors are connected in series the pow er supply output voltage is nearly twice the peak voltage from the transformer in this full wave voltage doubler circuit High voltage from the doubler circuit is connect ed to an output series resistor R3 as protec tion against output transients A current feed back signal is supplied to the control panel from the cathode of 1REC and voltage feedback signal is supplied through R2 Zener diodes 1DZ and 2DZ serve as voltage limiting devices in the event that the kV or cur rent feedback wires 31 or 34 become acciden tally disconnected from the LECU5003 Control Panel 13 CP 95 02 5 Ransburg MAINTENANCE A WARNING Electrical shock hazard ALWAYS turn power to
3. 4 Cad or Zinc 3 755 0 30 Hex Cable Assembly PTFE 4 Cord Shield LEPS4005 7 01 w 8 i i WBandBokClamp E 00 0 ontainer 1800300 Connection Kit for SSW 1064 cable LKITOOO3 00 Includes Items 9 11 12 and 35 O O Nut Retaining Screw Parts without part numbers may be purchased locally CP 95 02 5 18 LEPS5001 Power Supply Warranty Policies 19 Ransburg WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipmentthatfalls within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with Rans burg s written safety and operating instructions and has been used under normal operating con ditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG AP PROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THEAPPLICATOR ASSOCIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY FLUID HANDLING One 1 year from date of
4. Power Supply Appendix VISCOSITY CONVERSION CHART Z Id PPP OPE uewsyely sieas NSS lt yoqkes oiude160ujr1 CP 95 02 5 21 LEPS5001 Power Supply Appendix Ransburg a 23 2 x lt o 2 o nc gt o o 2 gt dng ueWIS eID SIeaS nss Iesi xi un SE AE SIN SISIE SIS e 9 oiude150ujr ET rst TTT 2 Note All viscosity comparisons are as accurate as e with existing information Comparisons are made with a material having a specific gravity of 1 0 22 CP 95 02 5 LEPS5001 Power Supply Appendix Ransburg VOLUMETRIC CONTENT OF HOSE OR TUBE English Units Length Section 003 gal 006 gal 010 gal 016 gal 032 gal 4 fl oz 8 fl oz 1 2 fl oz 2 0 fl oz 4 1 fl oz 3 16 007 gal 014 gal 022 gal 036 gal 072 gal 1E dE 1E dE H 013 gal 025 dab 038 gal 1064 dab 127 Gal sono sone zn scones 5 16 020 al 040 gar 060 gal 100 199 a ee eee 025 057 pd 086 cal 143 Ud 287 gal partes rara nome restos 051 Gal 102 Jal 153 gal 255 gal 510 TA e 3E PIECE VOLUMETRIC CONTENT OF HOSE OR TUBE Metric Units Length Section eomm oe ee e ee 36 9 cc 73 9 cc 110 8 cc 147 8 cc 184 7 cc 23 CP 95
5. Supply or Controller shutdown indicates Test only in areas free of flammable or combus a problem in the system requir tible materials ing correction The current overload sensitivity if equipped MUST be set as described in the correspond ing section of the equipment manual Protec tion against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Fre quent power supply shutdown indicates a prob lem in the system which requires correction Always turn the control panel power off prior to flushing 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 accor dance with NFPA 33 EN 50176 Have fire extinguishing equipment readily avail able and tested periodically General Use and Improper operation or mainte Personnel must be given training in accordance Maintenance nance may create a hazard with the requirements of NFPA 33 EN 60079 0 Personnel must be properly Instructions and safety precautions must be trained in the use of this equip read and understood prior to using this equip ment ment Comply with appropriate local state and na tional codes governing ventilation fire protec tion operation maintenance and housekeep ing Reference OSHA NFPA 33 EN No
6. equipment OFF prior to cleaning or servicing any part of the system Failure to do so could result in serious injury or death Whenever removing high voltage cable s from equipment ground the plug end of the cable s by contacting the plug to electrical ground Do not touch the plug until it has been grounded This will eliminate the possibility of residual charge causing electrical shock Whenever the high voltage cable is removed from the LEPS5001 Power Sup ply ALWAYS discharge any residual high voltage charge from the power supply by attaching an appropriate ground wire to the grounded power supply container and then inserting it down the free end of the high voltage tube gt assure continuous efficient trou ble free operation of the LEPS5001 Pow er Supply and to extend its service life keep the exterior clean and dry It is also very important to keep the areas around the high voltage cable connections clean to protect against static discharges Periodically clean the unit with a clean dry lint free cloth and visually inspect for any loose wiring connections Remove the high voltage cables make sure that they are clean and reinsert into the power supply CP 95 02 5 LEPS5001 Power Supply Maintenance NOTE gt Apply a liberal amount of dielectric grease 59972 00 to the high voltage ca ble plug before inserting back into the pow er supply Make sure that the high voltage cabl
7. kVDC the problem is with the high voltage cable junction tank or switch tank if installed or the spray applicator Consult the appropriate service manual for trouble shooting procedures If the 20791 high voltage test probe does not read approximately 70 kVDC the problem is with the LEPS5001 Pow er Supply If the LEPS5001 Power Supply has been isolated as the problem contact your authorized Ransburg representa tive for repair or replacement CP 95 02 5 Ransburg LEPS5001 Power Supply Parts Identification PARTS IDENTIFICATION 50131 52 26 Figure 5a LEPS5001 Power Supply CP 95 02 5 16 LEPS5001 Power Supply Parts Identification Ransburg Figure 5b Top View of LEPS5001 Power Supply 17 CP 95 02 5 Ransburg LEPS5001 Power Supply Parts Identification LEPS5001 POWER SUPPLY PARTS LIST Figure 5 Terminal Block End 7987 00 Terminal Block 7988 00 Lockwasher Spring 5 16 Cad or Zinc Pl d Nut 8 x 17 64 d Cad High Voltage Cable SSW 1064 Rubber Bushing Tapered 0006 High Voltage Adapter LEPS0005 Nut 96 00 5 4245 0 x Head Slot Machined Cad Pl 857 00 Screw 5 16 18 x 1 Hex Head Cap 16 Eyebolt 7 8 5 16 18 Dipstic Jum onBox T unction Box Lid 6 4 crew 1 4 20 x 1 Hex Head Zinc L ockwasher 1 4 Cad or Zinc PI W 8230 Washer Flat 1
8. purchase i e Totalizer CCV Valves etc AIR BEARING ROTATORS Fifteen thousand 15 000 hours or three 3 years whichever occurs first Warranty period begins on the date of purchase RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP ORMATERIALS THEREARE NOIMPLIED WARRANTIES NORWARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAM AGE TO PROPERTY OR FOR CONSEQUEN TIALDAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg will assume no responsibility for repair or replacement of the item or items The purchas er therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable CP 95 02 5 Ransburg APPENDIX LEPS5001 Power Supply Appendix PAINT AND SOLVENT SPECIFICATIONS RECOMMENDED VISCOSITY USING A ZAHN NO 2 REA EFM 18 TO 30 SEC REM M90 18 TO 30 SEC NO 2 HAND GUN 20 TO 60 SEC TURBODISK 20 TO 60 SEC AEROBELL II AEROBELL AEROBELL 33 RMA 101 20 TO 60 SEC PAINT ELECTRICAL RESISTANCE 1MQ TO gt 1MQ TO gt 1 TO
9. the possibility of residual charge causing electri cal shock Cut the high voltage cable SSW 1064 ac cording to the length required and screw an EPS 4245 connector supplied as part of the LKITOOO3 Connection Kit onto the cable end which will be inserted into the power supply Be careful to keep the screw centered in the middle of the cable as it is installed Thread the cable end through the metal nut and then through the rubber bushing supplied as part of the 0003 Kit Insert the cable fully into a high voltage output of the power supply then tighten the nut until the cable is secure Tighten the nut retaining screw with very light force see Figure 4 An LKIT0003 00 Connection Kit is required for each high voltage cable connection to the power supply or junction tank when using SSW 1064 cable NOTE gt Ifa high voltage junction tank or switch tank is to be used in the system refer to the appropriate service manual for cable terminations and installation requirements CP 95 02 5 10 LEPS5001 Power Supply Installation Ransburg 118VAC MAX 4 AMP MAX FROM CONTROL PANEL TO CONTROL PANEL ep UJ 5 2 A MOT1SA R2 R1 K V OUTPUT Figure 3 Schematic of LEPS5001 Power Supply Showing Connections to LECU5003 Control Panel 11 CP 95 02 5 LEPS5001 Power Supply Installation Ransburg S N NI OLLO3NNOO
10. 02 5 Ransburg LEPS5001 Power Supply Manual Change Summary MANUAL CHANGE SUMMARY This manual was published to replace Service Manual CP 95 02 4 LEPS5001 Power Supply to make the following changes 1 Revised Contents page 2 Revised Warranty Policies section under Equipment 3 Revised Volumetric Content of Hose or Tube chart in Appendix 4 Updated information on back cover CP 95 02 5 24 Service Manual Price 30 00 U S Automotive Systems 48152 West Road Wixom Michigan 48393 Telephone 248 668 8900 Fax 248 668 2160 Order Desk Telephone 877 852 7797 Fax 877 852 7796 Technical Service Assistance Telephone 800 626 3565 Fax 877 852 7796 Industrial Systems 320 Phillips Avenue Toledo Ohio 43612 1493 Telephone 419 470 2000 Fax 419 470 2270 Website www ransburg com E Mail marketing ransburg com Order Desk Telephone 800 726 8097 Fax 800 359 2341 Technical Service Assistance Telephone 800 233 3366 Fax 419 470 2071 2013 Ransburg USA Trademarks indicated with are registered with the United States Patent and Trademark Office by Ransburg Ransburg Industrial Systems is an ISO 9001 compliant company PR Form No CP 95 02 5 registered with Factory Mutual Models and specifications subject to ISO 9001 Litho in U S A change without notice Quality Systems 04 13
11. 1 M 1 MQ TO gt 1 MQ TO gt RECOMMENDED DELIVERY UP TO 1000 cc min 1500 cc min 180 cc min 1000 cc min 500 cc min GUIDE TO USABLE SOLVENT SELECTION CHEMICAL COMMON CATEGORY CAS EVAP NAME NAME NUMBER RATE Chlorinated Solvents DICHLOROMETHANE Methylene Chloride 75 09 2 ELECTRICAL RESISTANCE HIGH METHYL ACETATE Esters 79 20 9 LOW VM amp P NAPHTHA Naptha Aliphatic Hydrocarbons 803 232 4 HIGH ACETONE Ketones 67 64 1 LOW BENZENE Aromatic Hydrocarbons 71 43 2 Esters 141 78 6 MEDIUM 2 BUTANONE MEK Ketones 78 93 3 MEDIUM ISO PROPYL ACETATE Esters 108 21 4 LOW ISOPROPYL ALCOHOL IPA Alcohols 67 63 0 LOW 2 PENTANONE MPK Ketones 107 87 9 MEDIUM METHANOL Methyl Alcohol Alcohols 67 56 1 LOW PROPYL ACETATE n Propyl Acetate Esters 109 60 4 LOW TOLUOL Toluene Aromatic Hydrocarbons 108 88 3 HIGH METHYL ISOBUTYL KETONE MIBK Ketones 108 10 1 MEDIUM ISOBUTYL ACETATE Esters 110 19 0 LOW ETHANOL Ethyl Alcohol Alcohols 64 17 5 LOW BUTYL ACETATE Esters 123 86 4 LOW ETHYLBENZENE Aromatic Hydrocarbons 100 41 4 1 PROPANOL n Propyl Alcohol Alcohols 71 23 8 LOW 2 BUTANOL se
12. 4 Always properly support cables at least wiring grommets located on the bottom of the 12 inches from metal beams The sup control panel and connect to the control panel port should be made of material that terminal block as described in Figure 1 After does not conduct electricity such as making the connections tighten the external most plastics Ransburg part number wiring grommet around the black heat shrunk 45773 011 is one such support portion of the control cable In general con duit should be used to route the control cable 5 Always route cables from overhead check your local codes for conduit require down to the applicator ments Figure 3 shows a schematic of the LEPS5001 Power Supply and its connections to CAUTION the LECU5003 Control Panel A gt Do NOT make the approach to the ap NOTE plicator at or below floor level Route high voltage cables from overhead down to the gt The LEPS5001 Power Supply can also applicator Routing the cables up and out be used with older model 17264 Control of the way will result in less exposure to Panels For wiring connections refer to dirt and traffic Figure 2 6 If an insulating sheathing is used around HIGH VO LTAGE CABLE the cable it MUST be of a nonabsor bent material such a polyethylene and should be routed to prevent contact with or entrapment of solvents or cleaning SSW 1064 solutions The cable should NOT be sheathed from its last point of physical Unsh
13. CU5003 Control Panel Consult the Troubleshooting section of the LECU5003 Control Panel manual for appropriate troubleshooting procedures If the RMS voltage indicated on the volt meter is approximately 60 VAC contin ue troubleshooting as follows Turn the high voltage OFF at the control panel Remove the AC voltmeter from TB2 Remove the high voltage cable s from the power supply Set up a calibrated Ransburg High Volt age Test Probe and Meter 20791 with AWARNING Whenever removing high voltage ca ble s from equipment ground the plug end of the cable s by contacting the plug to electrical ground Do not touch the plug until it has been grounded This will eliminate the possibility of residual charge causing electri cal shock the 3 8 diameter high voltage cable at tachment see 20791 High Voltage Test Probe and Meter service manual for setups and procedures Connect the 20791 high voltage test probe ground clamp to a true earth ground insert the cable end of the test probe into the power supply high voltage tube and turn the test probe on 8 Ransburg Put the LECU5003 Control Panel into the high voltage on condition and turn its high voltage adjust knob to mid range 9 10 Ensure that the cable end of the test probe is fully inserted into the high voltage tube and tighten the strain relief connection If the 20791 high voltage test probe dis play reads approximately 70
14. SERVICE MANUAL Ransburg 95 02 5 Replaces CP 95 02 4 LEPS5001 POWER SUPPLY For Control Panel Model LECU5003 _ Ransburg MODEL LEPS5001 APPROVED IMPORTANT Before using this equipment care fully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 30 00 U S LEPS5001 Power Supply Safety Ransburg NOTE This manual has been changed from revision CP 95 02 4 to revision CP 95 02 5 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual CP 95 02 5 Ransburg CONTENTS LEPS5001 Power Supply Contents PAGE SAFETY 1 5 SAFETY PRECAUTIONS e 1 HAZARDS SAFEGUARDS n 2 5 INTRODUCTION 6 7 GENERAL DESCRIPTION 6 SPECIFICATIONS 7 INSTALLATION 8 12 Vote us u uu 8 SAFETY GROUND 8 CONNECTIONS TO LECU5003 CONTROL PANEL 9 HIGH VOLTAGE CABLE sen 9 10 LEPS5001 POWER SUPPLY SCHEMATIC 11 HIGH VOLTAGE CONNECTIONS 12 OPERATION 13 THEORY OF OPERATION re 13 MAINTENANCE 14 15 TROUBLESHOOTING cnn 14 15 PARTS IDENTIFICATION 16 18 LEPS5001 POWER SUPPLY s 16 TOP VIEW OF LEPS5001 POWER SUPPLY
15. c Butyl Alcohol Alcohols 18 92 2 LOW XYLOL Xylene Aromatic Hydrocarbons 133 02 07 HIGH AMYL ACETATE Esters 628 63 7 MEDIUM 2 METHYLPROPANOL iso Butyl Alcohol Alcohols 78 83 1 LOW METHYL AMYL ACETATE Esters 108 84 9 LOW 5 METHYL 2 HEXANONE MIAK Ketones 110 12 3 MEDIUM 1 BUTANOL n Butyl Alcohol Alcohols 71 36 3 LOW 2 ETHOXYETHANOL Glycol Ethers 110 80 5 LOW 2 HEPTANONE MAK Ketones 110 43 0 MEDIUM CYCLOHEXANONE Ketones 108 94 1 MEDIUM AROMATIC 100 SC 100 Aromatic Hydrocarbons HIGH DIISOBUTYL KETONE DIBK Ketones 108 83 8 MEDIUM 1 PENTANOL Alcohol Alcohols 71 41 0 LOW DIACETONE ALCOHOL Ketones 123 42 2 LOW 2 BUTOXYETHANOL Butyl Cellosolve Glycol Ethers 111 76 2 al CYCLOHEXANOL Alcohols 108 93 0 AROMATIC 150 SC 150 Aromatic Hydrocarbons d AROMATIC 200 Aromatic Hydrocarbons HIGH CAS Number Chemical Abstract Service Number Using the Ransburg Meter Solvent base Configuration Only t Information Obtained From http solvdb ncms org Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1 0 NOTE This page provides resistivity determination and control information that we feel is necessary when using Ransburg equipment CP 95 02 5 2013 Ransburg 20 Ransburg LEPS5001
16. cess to be at high voltage must be grounded Grounded conductive flooring must be provided in the spray area Always turn off the power supply prior to flush ing cleaning or working on spray system equip ment Unless specifically approved for use in hazard ous locations all electrical equipment must be located outside Class or Il Division 1 or 2 haz ardous areas in accordance with NFPA 33 LEPS5001 Power Supply Safety AREA Tells where hazards may occur Electrical Equipment hem e Toxic Substances Spray Area HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is uti lized the process Arcing in the vicinity of flammable or combustible materials may oc cur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequent power supply shut down indicates a problem in the system which requires correc tion An electrical arc can ignite coat ing materials and cause a fire or explosion 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 1 1 1 roethane not chemically compatible with the aluminum that might be used in many sys tem comp
17. ensitivity must be properly set as described in the Safety Overload Adjustment section of the LECU5003 Control Panel manual to ensure safe operation All components of this power supply were design selected for reliable heavy duty service The components including the high voltage transform er operate immersed in high quality non pcb dielectric oil to insulate against corona discharge and provide heat dissipation Systems include butare notlimited to the following LEPS5001 02 High Voltage Power Supply LECU5003 01 or 02 Control Panel CP 95 02 5 LEPS5001 Power Supply Introduction TheLECUS5003 01 and 02 Control Panels when connected to the LEPS5001 02 Power Supply will generate an unregulated output voltage of up to 100 kV Remote push button ON OFF Station Remote Alarm Bell High Voltage Cable Air Logic Station High Voltage Junction Tank Ahigh voltage junction tank accepts high voltage input from one output of the LEPS5001 Power Supply and provides multiple high voltage out puts to supply multiple applicators Consult the appropriate junction tank service manualor your authorized Ransburg representative for further information High Voltage Switch Tank A high voltage switch tank provides a means of discharging residual charge from the appli cator s when the control panel is turned off or an overload condition occurs The switch tank accepts high voltage input from one output of the LEPS5001 Pow
18. er Supply and independently controls high voltage to two outputs When the system is operating normally the switch tank passes high voltage from its input to its output When the system is turned off or an overload occurs the switch tank automatically grounds the applicator Consult the appropriate switch tank service manual or your authorized Rans burg representative for further information LEPS5001 Power Supply Introduction Ransburg SPECIFICATIONS NOTES Environmental Physical Nominal Dimensions 21 diameter x 28 height 53 m diameter x 71 m height Weight 254 Ibs 115 2 kg including 28 gallons 90 8 liters of dielectric oil Electrical AC Input 0 to 120 Volts AC from LECU5003 Control Panel DC Output Maximum Continuous Operating Voltage 100 kV Current 0 100 kV 2500 pA max CP 95 02 5 Ransburg INSTALLATION LOCATION WARNING The LEPS5001 Power Supply MUST be located outside the hazardous area see NFPA Bulletin No 33 The user should be aware of and adhere to all local building codes and ordinances gt 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 requirements for oper ating and servicing safely are followed Install the LEPS5001 Power Supply in a con venient area outside the hazardous location where it will be protected from the poss
19. es are fully inserted into the power supply and that the strain relief connections are se cure TROUBLESHOOTING A WARNING Field repair and troubleshooting of the LECU5003 Control Panel may require expo sure to potentials that can cause SERIOUS BODILY INJURY or DEATH if proper pro cedures are not followed For this reason troubleshooting and field repair should only be accomplished with specific test equip ment by qualified electronics technicians or authorized Ransburg representatives in Figure 3 illustrations in Figures 5a and 5b Theory of Operation and Parts Identification sections of this manual and the LECU5003 Control Panel service manual If a high voltage output problem is suspected in the system perform the following troubleshoot ing procedure Equipment required Ransburg High Voltage Test Probe and Meter 20791 AC RMS Voltme ter 150 volt scale or greater 1 With the power OFF remove the cov er from the junction box that houses 14 LEPS5001 Power Supply Maintenance 15 terminal block 2 TB2 on top of the LEPS5001 Power Supply Check for any loose wiring connections to TB2 Connect an AC RMS voltmeter 150 volt scale or greater from TB2 4 to TB2 5 Put the LECU5003 Control Panel into the high voltage on condition and turn its high voltage adjust knob to mid range If the RMS voltage indicated on the volt meter is not approximately 60 VAC the problem is with the LE
20. ibility of any contact with water vapor or high humidity and ambient temperatures in excess of 120 F The area should be clean dry and well ventilated LECU5003 CONTROL PANEL CONNECTIONS White 17 pesi 5 Ii j NN Bi MCN Figure 1 LECU5003 Control Panel Connections From LEPS5001 TB2 Terminal AC Neutral a 1 AC Hot 5 6 31 CP 95 02 5 LEPS5001 Power Supply Installation gt Donot locate the LEPS5001 Power Supply near or adjacent to heat producing equipment such as ovens high wattage lamps steam pipes etc SAFETY GROUND Crimp the appropriate connector onto the Ground Wire Assembly Part No 70539 sup plied and install from the Power Supply ground stud G1 see Figure 5 to a true earth ground Ground Wire Assembly MUST connected from the Power Supply ground stud to a true earth ground 17264 CONTROL PANEL CONNECTIONS Terminal Description Accom HOT m qasan EV Fak Feta round T cenecrumrsmenm Figure 2 17264 Control Panel Connections LEPS5001 Power Supply Installation Ransburg CONNECTIONS 2 Never route cables from different power supplies along parallel paths unless they TO LECU5003 are separated by at least 18 inches CONTROL PANEL 4 Always route cables along appropriate insulators Route the control cable from the LEPS5001 Power Supply through one of the external
21. ielded High Voltage Cable support after it enters the spray area to the applicator Insulating sheathing is ROUTING amp GENERAL GUIDELINES According to OSHA standard 1910 107 h 5 available from Ransburg as part number high voltage cable shall be properly insulated 9704 13 and protected from mechanical injury or ex posure to destructive chemicals To facilitate 7 If a cable must be routed through a met compliance with this code the following recom al or conductive surface cut an open mendations must be followed ing with a minimum radius of five inches and mount a nonconductive bulkhead 1 Never route cables so that they lie on therein Route the cable through the the floor or are subject to vehicular traffic center of the bulkhead and secure it with a suitable nonconductive strain relief The opening may be any configuration as long as there is at least five inches gt Sheathing is NOT a safe method of pro from the nearest conductor tecting a cable from wear or traffic 9 CP 95 02 5 AWARNING Ransburg LEPS5001 Power Supply Installation 8 Make cable runs as short as possible by NOTES mounting the power supply as close to the spray device as codes and environ ment allow A WARNING Whenever removing high voltage ca ble s from equipment ground the plug end of the cable s by contacting the plug to electrical ground Do not touch the plug until it has been grounded This will eliminate
22. ire high voltage to be on but only as instructed Non factory replacement parts or unautho rized equipment modifications may cause fire or injury If used the key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks dis abled Never use equipment intended for use in water borne installations to spray solvent based ma terials 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 LEPS5001 Power LEPS5001 Power Supply Safety anspurg AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Spray Area Explosion Hazard Improper or inadequate oper Electrostatic arcing must be prevented Safe ation and maintenance proce sparking distance must be maintained between dures will cause a fire hazard the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage Protection against inadvertent is required at all times arcing that is capable of caus ing fire or explosion is lost if Unless specifically approved for use in hazard any safety interlocks are dis ous locations all electrical equipment must be abled during operation located outside Class or Il Division 1 or 2 hazardous areas in accordance with NFPA 33 Frequent Power
23. m equipment during spraying flushing 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 CP 95 02 5 Ransburg INTRODUCTION GENERAL DESCRIPTION The LECU5003 Control Panel and LEPS5001 Power Supply produce 0 to negative 100 kVDC continuous operating voltage The two outputs of the LEPS5001 Power Supply provide spray devices with up to 2500 microamps at 100 kV This heavy duty source of high voltage provides for rugged reliable operation a variety of industrial finishing applications The LEPS5001 Power Supply is Factory Mutual Approved when used with the LECU5003 01 or LECU5003 02 Control Panel for Aerobell rotary atomizer and REA III automatic systems Ref erence the LECU5003 manual or contact your local Ransburg representative for more details Amaximum allowable current level is selected by the user on the Sensitivity Module located inside the LECU5003 Control Panel The Sensitivity Module circuit determines if the power supply output current exceeds the desired maximum current as set on the Sensitivity Module If so the control panel immediately enters an overload condition which de energizes the high voltage The sense circuitry is sufficient to eliminate most possible arcing conditions however the overload s
24. maintenance procedures will cause a fire hazard Protection against inadver tent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during opera tion Frequent Power Supply or Controller shutdown indi cates a problem in the system requiring correction LEPS5001 Power Supply Safety 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 flushing or main tenance When using solvents for cleaning Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 100 F 37 8 Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA country and local codes In addition ventilation must be main tained during cleaning operations using flam mable or combustible solvents Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times Test only in areas free of combustible material Testing may requ
25. onents The chemical reaction caused by these sol vents reacting with aluminum can become violent and lead to an equipment explosion Ransburg SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for use in hazard ous locations the power supply control cabinet and all other electrical equipment must be locat ed outside Class or II Division 1 2 hazard ous 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 flammable or combus tible 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 Follow the requirements of the Material Safety Data Sheet supplied by coating material manu facturer 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 appli cation equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents must never be used with aluminu
26. rms and your insurance company requirements 3 CP 95 92 5 Ransburg AREA Tells where hazards may occur Spray Area High Voltage Equipment CP 95 02 5 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 fire or explosion LEPS5001 Power Supply Safety 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 con veyors or hangers that are properly ground ed The resistance between the part and earth ground must not exceed 1 meg ohm Refer to NFPA 33 Operators must be grounded Rubber soled in sulating 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 ap plicator 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 re quired by the pro
27. this manual with your system installation draw ings and appropriate Ransburg equipment man uals 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 efficient 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 Ransburg WARNING gt The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified gt 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 fire codes and ordinances as well as NFPA 33 SAFETY STANDARD LATEST EDITION prior to installing operating and or servicing this equipment A WARNING gt The hazards shown on the following pages may occur during the normal use of this equip ment Please read the hazard chart beginning on page 2 CP 95 02 5 Ransburg AREA Tells where hazards may occur Spray Area CP 95 02 5 HAZARD Tells what the hazard is Fire Hazard Improper or inadequate operation and
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