Graco 333233D, Electric Driver for High Pressure Airless Sprayer Repair, Parts Owner's Manual

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Graco 333233D, Electric Driver for High Pressure Airless Sprayer Repair, Parts Owner's Manual | Manualzz
Repair-Parts
Electric Driver for
High Pressure Airless Sprayer
333233D
EN
Electric driver for application of protective coatings. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Model 24V016
WLD
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Vented Oil Cap Before Using Equipment .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance Schedule . . . . . . . . . .
Change the Oil . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Pre-Load . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Saving Mode . . . . . . . . . . . . . . . . . . . . . .
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
5
5
5
6
7
7
7
7
8
8
8
8
8
9
9
9
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replace Shaft Bearing Assembly . . . . . . . . . . . 12
Replace Fan Fuses . . . . . . . . . . . . . . . . . . . . . . 13
Replace Fan Assembly . . . . . . . . . . . . . . . . . . . 13
Replace Electronics Cover . . . . . . . . . . . . . . . . 15
Repair Token Cable . . . . . . . . . . . . . . . . . . . . . . 18
Software Update Procedure . . . . . . . . . . . . . . . 19
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electric Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts List - Electric Driver (24V016) . . . . . . . . . 21
Mounting Hole Pattern . . . . . . . . . . . . . . . . . . . . 22
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26
Related Manuals
Manuals are available at www.graco.com.
Component manuals in English:
333208
2
Electric High Pressure Sprayer Manual
333233D
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
333233D
3
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your
material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow
the Pressure Relief Procedure and disconnect all power sources.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury,
hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
4
333233D
Installation
Installation
2. Bring cord to unit and remove four screws to separate junction box cover (G) with power switch (E)
from remainder of sprayer. See FIG. 2.
Improper wiring may cause electric shock or other
serious injury. All electrical wiring must be done by a
qualified electrician and comply with all local codes
and regulations.
2))
S
G
Power Supply
E
See Table 1 for power supply requirements. The system
requires a dedicated circuit protected with a circuit
breaker.
Table 1: Power Supply Specifications
Voltage
Phase
Hz
Current
200-240 VAC
1
50/60
20 A
Select the minimum cord wire gauge based on length
according to the table below:
Length
50 ft (15.24 m)
100 ft (30.48 m)
200 ft (60.96 m)
300 ft (91.44 m)
mm2
3.31
5.26
13.29
21.14
Gauge
12 AWG
10 AWG
6 AWG
4 AWG
WLD
FIG. 2: Power Switch
3. With power switch (E) and junction box cover (G)
detached from machine, wires inside junction will
appear as below.
NOTE: Two wires will be installed in both terminals.
See FIG. 3:
• For Series A and B: terminals 1L1 and 3L2
• For Series C: terminals 1L1 and 5L3
NOTE: Press gasket against back sealing face of
junction box to ease installation of power cord.
Connect Power
1. Cut power cord wires to the following lengths:
• Ground wire - 6.5 inches (16.5 cm)
• Power wires - 3.0 inches (7.6 cm)
• Add ferrules as necessary. See FIG. 1.
7
/
7
/
7
/
G
WLE
LQ
FIG. 3: Terminal Connections
4. Insert power cord (from step 1) through cord grip
(C2) and into junction box (S).
LQ
POWER
FIG. 1: Power Cord
333233D
C2
WLD
GROUND
NOTE: Power wires should be installed into terminals. See FIG. 3:
• Series A and B: terminals 2T1 and 4T2
• Series C: terminals 2T1 and 6T3
5
Installation
5. Attach ground wire to ground terminal inside junction box (S).
NOTE: The power cord attaches to a separate
ground screw than the ground screw that is already
attached.
7. Replace junction box screws and washers removed
in step 2 and tighten cord grip to securely hold
power cord in junction box (S). See FIG. 5.
S
WLE
6. Place fan wires and other power wires into open
area on either side of disconnect block (J) as space
permits. Reinstall junction box cover. See FIG. 4.
NOTICE
If wires get pinched when the screws are tightened,
damage will occur. Make sure all wires are routed
correctly before installation.
G
WLD
FIG. 5: Junction Box Screws and Strain Relief
Grounding
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
J
Driver: The driver is grounded through the power cord.
E
WLD
FIG. 4: Grounding Wire
6
333233D
Setup
Install Vented Oil Cap Before
Using Equipment
The driver gear-box is shipped from the factory pre-filled
with oil. The temporary unvented cap (PX) prevents oil
leaks during shipment. This temporary cap must be
replaced with the vented oil cap (P), supplied with the
equipment, before use.
PX
P
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
1. Pull pressure adjustment knob (H) out and turn
counterclockwise until it stops. Push the knob in to
lock.
2. Relieve all fluid pressure as explained in your separate sprayer manual.
ti31010a
FIG. 6: Unvented and Vented Oil Caps
Operation
Setup
1. Pull pressure adjustment knob (H) out and turn
counterclockwise until it stops. Push the knob in to
lock.
The motor will adjust the speed to maintain a constant
fluid pressure.
1. Pull the control knob (H) out to set. Turn the knob
clockwise to increase the pressure, or
counter-clockwise to decrease the pressure. Push
the knob to lock. See FIG. 7.
H
ti20171a_1
FIG. 7: Pressure Adjustment Knob
2. Turn power switch (E) OFF. Connect unit to power
source. See FIG. 2, page 5.
333233D
7
Maintenance
Maintenance
NOTICE
Do not open/remove gear cover. The gear side is not
intended to be serviced. Opening the gear cover may
alter the factory set bearing pre-load and may reduce
the product life.
Preventative Maintenance
Schedule
Check Oil Level
Check the oil level in sight glass (K). (See FIG. 8.) The
oil level should be near the halfway point of the sight
glass when the sprayer is not running. If oil is low, open
fill cap (P) and add Graco Part No. 16W645 ISO 220 silicone-free synthetic EP gear oil. See FIG. 8.
The oil capacity is approximately 1.0 - 1.2 quarts (0.9 1.1 liters). Do not overfill.
NOTICE
The operating conditions of your particular system
determine how often maintenance is required. Establish
a preventative maintenance schedule by recording when
and what kind of maintenance is needed, and then
determine a regular schedule for checking your system.
Only use oil with Graco part number 16W645. Any
other oil may not lubricate properly and can cause
damage to the drive train.
P
Change the Oil
NOTE: Change the oil after a break-in period of 200,000
to 300,000 cycles. After the break-in period, change the
oil once per year.
R
1. Place a minimum 2 quart (1.9 liter) container under
the oil drain port. Remove the oil drain plug (15).
Allow all oil to drain from the driver.
2. Reinstall the oil drain plug (15). Torque to 18-23 ft-lb
(25-30 N•m).
3. Open the fill cap (P) and add Graco Part 16W645
ISO 220 silicone-free synthetic EP gear oil. Check
the oil level in the sight glass (K). (See FIG. 8.) Fill
until the oil level is near the halfway point of the sight
glass. The oil capacity is approximately 1.0 - 1.2
quarts (0.9 - 1.1 liters). Do not overfill.
K
WLE
FIG. 8: Sight Glass and Oil Fill Cap
Bearing Pre-Load
See FIG. 8. The bearing pre-loads (R) are factory set
and are not user adjustable. Do not adjust the bearing
pre-loads.
4. Reinstall the fill cap.
8
333233D
Troubleshooting
Troubleshooting
Error Codes
Error codes can take two forms:
Alarm: alerts you to the alarm cause and shuts down
the pump.
Power Saving Mode
When fast blinking is displayed, the sprayer has entered
Power Saving Mode mode. When the sprayer is on and
pressurized but the pump has not moved any material in
30 minutes, the sprayer will enter Power Saving Mode
and will only control up to 75% of the maximum pressure.
Deviation: alerts you to the problem, but pump may
continue to run past the set limits until the system’s
absolute limits are reached.
NOTE: The blink code is displayed using the power indicator (L) on the driver. The blink code given below indicates the sequence. For example, blink code 2 indicates
two blinks, a pause, and then the sequence repeats.
Power Saving Mode will be exited when:
•
/
Material starts to dispense and causes the pump to
move, OR
The pressure knob is adjusted, OR
Power is cycled OFF and ON
•
•
(
WLD
NOTE: To clear an error code, first try turning the pressure adjustment knob (H) counterclockwise until it stops.
If the status indicator (L) does not stop blinking shortly
after turning the knob to zero, cycle the power by turning
the power switch (E) to the off position for at least 30
seconds before turning it back on.
Blink Code
Error Type
Troubleshooting Steps
1
Alarm
Voltage Too Low
• Verify that line voltage is within the range specified in Technical Data, page 24.
• Use the recommended cord (see page 5).
• Cycle power and check status indicator to see if error is still active.
2
Alarm
Voltage Too High
• Verify that line voltage is within the range specified in Technical Data, page 24.
• Cycle power and check status indicator to see if error is still active.
• Verify that the outlet check valve is installed on pump and functions properly. A
faulty outlet check valve can result in excessive pump speed, causing high voltage internally to the electric driver.
3
Deviation
•
•
333233D
Low Temperature
Warm equipment.
Contact your Graco distributor or Tech Service for more information.
9
Troubleshooting
Blink Code
Error Type
4
Deviation
High Temperature
The temperature of the system is near the maximum operation temperature. The
performance has been reduced to prevent the sprayer from completely shutting
down.
• Check fan operation. Clean fan and driver housing. Verify fuses are intact in junction box.
• Reduce pressure, duty cycle, or gun tip size.
• Move unit to a cooler location.
5
Alarm
Motor Temperature Fault
Motor is running too hot. Allow unit to cool.
• Check fan operation. Clean fan and driver housing. Verify fuses are intact in junction box.
• Reduce pressure, duty cycle, or gun tip size.
• Move unit to a cooler location.
6
Alarm
Board Temperature Fault
The control board is running too hot. Allow unit to cool.
• Check fan operation. Clean fan and driver housing. Verify fuses are intact in junction box.
• Reduce pressure, duty cycle, or gun tip size.
• Move unit to a cooler location.
7
Alarm
8
9
Troubleshooting Steps
•
•
•
Encoder Calibration Error
Cycle power and check status indicator to see if error is still active.
Calibrate the encoder (see page 17).
Contact your Graco distributor or Tech Service for more information.
•
•
•
•
Encoder Error
Cycle power and check the status indicator to see if the error is still active.
Verify that the encoder cable is connected securely.
The encoder may need to be replaced.
Contact your Graco distributor or Tech Service for more information.
Alarm
Alarm
•
10
Alarm
11
Alarm
12, 13
Fast Flash
10
Circuit Board Communication Failure
• Cycle power and check status indicator to see if error is still active.
• Contact your Graco distributor or Tech Service for more information.
•
•
Internal Circuit Board Hardware Failure
Cycle power and check status indicator to see if error is still active.
Contact your Graco distributor or Tech Service for more information.
•
•
Internal Software Error
Cycle power and check status indicator to see if error is still active.
Contact your Graco distributor or Tech Service for more information.
Alarm
Deviation
Software Versions Do Not Match
Obtain software update token and follow Software Update procedure
(contact your Graco distributor or Tech Service for more information).
See Power Saving Mode, page 9.
333233D
Troubleshooting
Problem
Cause
Solution
Driver does not turn
over and LED is off
Over voltage (greater than 300 V)
•
Check power supply
No power to control board
•
Contact your Graco distributor or Tech Service
for more information.
Driver does not turn
over and LED is on
Encoder fault
•
•
Cycle power.
Contact your Graco distributor or Tech Service
for more information.
Oil is leaking
Oil was over-filled
•
Drain and refill as stated in Check Oil Level,
page 8.
Drain plug not tightened properly
•
Torque to 18-23 ft-lb (25-30 N•m).
Seal cartridge o-ring missing or damaged.
•
Replace shaft bearing assembly.
333233D
11
Repair
Repair
1. Stop pump at bottom of its stroke. Shut off and
remove power to driver.
2. Perform Pressure Relief Procedure, page 7.
To prevent skin injection and splashing, never open a
camlock hose or applicator fitting while there is
pressure in the fluid line. Perform Pressure Relief
Procedure, page 7, before performing any repair
procedure.
Replace Shaft Bearing
Assembly
3. Disconnect lower from driver. See sprayer manual.
4. Drain oil from driver. See Change the Oil, page 8.
5. Reinstall oil drain plug. Torque to 18-23 ft-lb (25-30
N•m).
6. Unscrew shaft bearing assembly (14) from driver.
See Parts, page 20.
7. Install new shaft bearing assembly. Torque to
175-200 ft-lb (240-280 N•m).
8. Fill with oil. See Change the Oil, page 8.
NOTE: Series A drivers require a different shaft bearing
assembly part number. See Parts for the correct part
numbers.
12
9. Reconnect lower to driver.
10. Turn power ON and resume operation.
333233D
Repair
Replace Fan Fuses
Replace Fan Assembly
1. Perform Pressure Relief Procedure, page 7.
1. Perform Pressure Relief Procedure, page 7.
2. Disconnect unit from power source.
2. Disconnect unit from power source.
3. Remove two screws (53) and remove junction box
cover (G) from driver to gain access to the disconnect block (J). Gently pull out fuse holders.
3. Remove two screws (53) and remove junction box
cover (G) from driver to gain access to the disconnect block (J). See FIG. 9.
4. Unscrew fuse holder, remove old fuse, and replace
with new fuse (Graco part number 116682) (5 mm x
20 mm, 500 mA, 250V, Slow Blow). Reconnect fuse
holder and tighten.
4. Loosen screws for 1L1 and 5L3 and gently remove
wires from each location.
G
NOTE: For Series A and Series B motors, use terminals 1L1 and 3L2.
J
53
7
/
7
/
7
/
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WLD
FIG. 9: Fuse Location
5. Repeat step 4 with second fuse.
6. Tuck wires back into junction box (S) around disconnect block (J) and reinstall junction box with two
screws and washers.
FIG. 10: Remove Wires
5. Use a wire cutter to cut ferrule tips from fan wires
and motor power wires close to ferrules.
NOTE: Do not cut the tip off of the ground wire.
See FIG. 10.
NOTE: Make sure no wires get pinched during
installation.
333233D
13
Repair
6. Remove grounding screw (GS) and disconnect
green grounding wire coming out of fan cord grip
(C1) attached to driver (not the junction box).
WLE
GS
9. Install new fan assembly. To reattach the fan assembly, slide cover into slots for tabs located on junction
box side and gently push down far end. Apply
thread locker and use supplied fasteners and washers. Torque to 15 - 20 ft-lb (20 - 27 N•m).
C1
FIG. 11: Grounding Screw
7. Loosen fan cord grip (C1) attached to driver and pull
out fan wires.
WLE
FIG. 14: Fan Assembly Installation
10. Route wires through fan cord grip (C1) attached to
driver (not the junction box (S)).
11. Reattach the ground wire to the grounding screw.
Tighten ground screw. See FIG. 11.
WLD
7
/
7
/
7
/
FIG. 12: Remove Fan Wires
WLD
8. Remove screws that attach fan assembly to driver
and pull up on end farthest from junction box. Slide
assembly toward junction box to remove.
12. Use a ferrule to connect each fan wire to one of two
wires coming out of the motor grommet. Then attach
one wire set into the disconnect box location 1L1
and the other wire into location 3L2. See FIG. 11.
13. Gently tuck wires back into junction box (S) around
disconnect block (J) and reinstall junction box cover
(G). Replace two screws (53) and washers, then
tighten. See FIG. 9, page 13.
NOTICE
If wires get pinched when the screws are tightened,
damage will occur. Make sure all wires are routed
correctly before installation.
WLD
NOTE: Make sure no wires get pinched during
installation.
FIG. 13: Fan Assembly Removal
14. Tighten cord grip attached directly to driver
assembly.
14
333233D
Repair
Replace Electronics Cover
Removal
7. Use a wire cutter to cut ferrule tips from fan wires
and motor power wires. NOTE: Cut the wires as
close to the ferrules as possible. Do not cut the tip
off of the ground wires.
1. Perform Pressure Relief Procedure, page 7.
2. Disconnect unit from power source.
3. Remove the lower from the sprayer (see the Sprayer
manual). NOTE: This is required to complete the
calibration procedure (page 17).
4. Remove two screws (6) and remove junction box
cover (5).
7
/
7
/
7
/
7
/
7
/
7
/
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FIG. 17: Disconnect Fan Wires
8. Use an adjustable wrench to loosen the fan cord
grip (C1).
51
5
6
WLE
FIG. 15: Junction Box Cover
5. Loosen cord screws on disconnect block (51) and
disconnect wires from locations 1L1 and 5L3.
C1
NOTE: On Series A and Series B motors, terminal
locations are 1L1 and 3L2.
NOTE: Power cord cables (excluding the ground
wire) may remain attached.
6. Unscrew ground screws from fan and power cord
ground wires.
WLD
FIG. 18: Loosen Cord Grip
9. Pull the fan wires out through the cord grip.
10. Remove four bolts (56) and washers, gasket (52),
and junction box sleeve (S).
52
S
56
WLD
WLD
FIG. 16: Ground Screw Location
333233D
FIG. 19: Junction Box Sleeve
15
Repair
11. Remove 12 screws (20) and washers from electronics cover (50).
50
14. Disconnect the stroke position sensor wire (H).
H
20
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WLD
FIG. 20: Electronics Cover Removal
FIG. 23: Stroke Position Wire
12. Carefully tilt electronics cover (50) down.
15. Disconnect the encoder wire (E).
50
E
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FIG. 21: Tilt Electronics Cover
NOTICE
All wires must be disconnected before the cover is
completely removed. Hold the cover in place while
disconnecting wires or let the cover rest on a work
surface to avoid damaging the wires and connections.
WLD
FIG. 24: Encoder Wire
16. Discard the used cover gasket (53) and the junction
box gasket (52).
13. Pull wire connectors down, out of the harness clip
and disconnect the motor power and motor temperature wires (M).
53
M
52
FIG. 22: Motor Wires
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FIG. 25: Electronics Cover and Junction Box Gaskets
16
333233D
Repair
Installation
7. Connect fan ground wire. See FIG. 19, page 15.
See FIG. 16, page 15.
1. Install the new cover gasket (included in the electronics cover kit). See FIG. 25, page 16.
8. Use an adjustable wrench to tighten the fan cord
grip (C1). See FIG. 18, page 15.
2. Reconnect all wires.
3. Install electronics cover (50) and tighten 12 screws
(20). Torque to 15-20 ft-lb (20-27 N•m). See FIG. 20,
page 16.
9. Install gasket (52), junction box sleeve (S), and
tighten four bolts (56). See FIG. 19, page 15.
10. Install junction box cover (G) and tighten two screws
(6). See FIG. 15, page 15.
NOTICE
If wires get pinched when the cover screws are tightened, damage will occur. Make sure all wires are positioned inside the cover before installation.
4. Install new junction box gasket.
5. Route fan cable through fan cord grip.
6. Connect the stripped fan wire to the motor wire and
crimp the wires together.
11. Install wires into disconnect switch (51) and tighten
wire screws.
NOTE: The lower must be removed from the system
in order to calibrate correctly. The calibration stroke
length is longer than the operating stroke. Leaving
the lower attached will cause the driver rod to contact the lower rod and it will not calibrate correctly.
12. Connect power cord.
13. Engage power.
7
/
7
/
7
/
WLD
FIG. 26: Install Fan Wires
333233D
17
Repair
Calibration
Repair Token Cable
NOTE: The driver must be de-coupled from the lower
and must be able to cycle freely with no obstructions.
1. Cycle power to the driver by first turning the power
switch (S) to OFF, and then to ON again.
2. Wait for the status indicator LED (L) to turn on solid
or start blinking.
3. Within 30 seconds, rapidly turn the pressure control
knob (N) back and forth from 0 to 10 at least five
times and then set the knob back to 0. If the status
indicator LED (L) was solid before, it will begin blinking an encoder calibration error (code 8) during the
calibration process.
4. The driver output shaft (H) will run up and down
slowly over the course of several minutes.
5. Midway through the auto-calibration process, the
driver output shaft (H) will pause as it moves to the
next step.
6. The driver output shaft (H) will move up and down
faster 5-6 times.
1. Perform Pressure Relief Procedure, page 7.
2. Disconnect unit from power source.
3. Remove 12 screws (20) and washers from
electronics cover (50). See FIG. 20, page 16.
4. Carefully tilt electronics cover (50) down.
See FIG. 21, page 16.
NOTICE
All wires must be disconnected before the cover is
completely removed. Hold the cover in place while
disconnecting wires or let the cover rest on a work
surface to avoid damaging the wires and connections.
5. Check the token wire (T) connections. Replace the
wire if it is damaged. NOTE: Make sure the token
wire connection is positioned with the wires facing
the bottom of the sprayer (as seen below).
7. Ensure the auto-calibration process is complete
before continuing. Wait for the LED to stop blinking.
T
WLD
FIG. 27: Token Wire
6. Install cover and tighten 12 screws (20) and washers. Torque to 15-20 ft-lb (20-27 N•m).
NOTICE
If wires get pinched when the cover screws are tightened, damage will occur. Make sure all wires are positioned inside the cover before installation.
7. Connect power cord.
18
333233D
Repair
Software Update Procedure
7. The red indicator light (L) will flash while the software is being loaded (approximately 30 seconds).
When the software is completely loaded, the red
light will turn off for four seconds before the software
version flashes. Then a solid light will stay on.
1. Perform Pressure Relief Procedure, page 7.
2. Disconnect unit from power source.
3. Remove two screws (53) and washers. Then
remove junction box cover (G) from driver to gain
access to the token slot (TS).
NOTE: Whenever the unit is powered on and the
token is present in the token slot, the indicator light
will flash the three series software code one time.
Example: 1.02.003 would be one blink, a pause, two
blinks, as pause, then three blinks. Normal operation will resume after the software version displays.
G
53
L
TS
WLD
FIG. 29: Red Indicator Light Location
FIG. 28: Token Slot Location
4. Insert and press token firmly into the slot.
NOTE: The token has no preferred orientation.
5. Tuck the wires back into the junction box (S) and
reinstall junction box cover (G) with two screws and
washers.
NOTICE
If wires get pinched when the cover screws are tightened, damage will occur. Make sure all wires are positioned inside the cover before installation.
6. Connect the unit to the power source and turn it ON.
8. Turn off the unit and disconnect from the power
source.
9. Remove two screws (53) and washers. Then
remove junction box cover (G) from driver to gain
access to the token slot (TS).
10. Remove the token from the slot.
11. Tuck the wires back into the junction box (S) and
reinstall junction box cover (G) with two screws and
washers.
NOTICE
If wires get pinched when the cover screws are tightened, damage will occur. Make sure all wires are positioned inside the cover before installation.
NOTE: The latest software version for each system can
be found by searching “Software Version Change History for 17N254” at Graco Technical Support. Contact a
technical support representative before upgrading.
333233D
19
Parts
Parts
Electric Driver
:
D
3
E
F
WLG
FIG. 30: Electric Driver Parts
20
333233D
Parts
Parts List - Electric Driver (24V016)
Ref.
1
2
5†
6†
7†
8*†
9
10
11
12
13
14
15
16
17▲
18
19▲
20*‡
21*‡
22
23*
50*
51
52
53*
55
56
69
96
Part
Description
Qty.
CHASSIS
1
15H392 ADAPTER, rod Xtreme
1
17B507 COVER, junction box
1
115264 SCREW, cap, socket head
2
104572 WASHER, lock spring
2
17B509 GASKET, cover, junction box
1
15H525 CAP, fill
1
TAG, oil
1
555448 PLUG, stl, 3/8 pipe hex
1
123971 KNOB, disconnect, operator
1
121171 GRIP, cord, .35-.63, 3/4
2
See Part 14 Table
15H432 PLUG, oil drain
1
24E315 SIGHT GLASS
16W360 LABEL, safety, warning
1
15F931 RING, lift, sst
1
16T764 LABEL, warning
1
109114 SCREW, cap, sch
31
104572 WASHER, lock, spring
28
24V224 COVER, fan, assy
1
(includes fan, cable and fasteners)
16U113 KNOB KIT
1
ELECTRONICS COVER
1
262657 SWITCH, power, 40A
1
16Y458 GASKET, junction box
1
16Y460 GASKET, side cover
1
108788 WASHER, flat
1
124165 SCREW, cap, socket head
1
LABEL, branding, Xtreme Z45
1
LABEL, branding, Xtreme Z25
1
127721 KNOB, impact control, preventer
1
Ref.
97
101‡
102
Part
127463
17B505
17B553
16Y491
104 16W645
116682
24W120
105▲ 195792
Description
SCREW, cap, socket head
SLEEVE, junction box
ERROR CODE LABEL
TOKEN CABLE (not shown)
GEAR LUBE
FUSE (not shown)
SENSOR, stroke position
LABEL, warning
Qty.
1
1
1
1
0
1
1
1
* 24W078 KIT, electronics, cover
(includes 8, (12x) 20, (12x) 21, 23, 50, 53, and ferrules)
† 127854 Junction Box Cover Kit
(includes 5, 8, (2x) 6, (2x) 7)
‡ 127855 Junction Box Sleeve Kit
(includes (4x) 20, (4x) 21, 101)
▲Replacement Warning labels, signs, tags, and cards
are available at no cost.
★ The driver gear-box is shipped from the factory
pre-filled with oil. Additional oil must be purchased separately.
Part 14 Table:
Driver 24V016 Part No.
Ref.
14
14a
14b
14c
Description
Series A
CARTRIDGE, out- 24K341✖
put seal
KIT, washer, support See Notice
KIT, bumper, lower 16K679✖
O-RING
108993
Series B &
Current
25C164
25C162
25C163
25C165
(pack of two)
✖ Kit 24K341 does not include part 14b. 16K679 must
be ordered separately.
NOTICE
Do not use a washer (14a) with Series A drivers.
Use of a washer may cause damage to seal (in cartridge 14c).
Part Specifications:
Ref.
333233D
Instruction
1
Torque to 20 - 27 N•m (15-20 ft-lb)
3
Torque to 240 -280 N•m (175-200 ft-lb)
4
Torque to 25-30 N•m (18-23 ft-lb)
5
Torque to 195-210 N•m (145-155 ft-lb). Apply serviceable medium thread locker.
21
Parts
Mounting Hole Pattern
'
&
%
WLD
$
FIG. 31: Mounting Hole Pattern
A
6.186 in. (157 mm)
B
6.186 in. (157 mm)
C
Four 3/8-16 Mounting Holes
D
Six 5/8-11 Tie Rod Holes:
• 8 in. (203 mm) x 120° bolt circle
OR
• 5.9 in. (150 mm) x 120° bolt circle
22
333233D
Wiring Diagram
Wiring Diagram
$,5)/2:',5(&7,21
72/
72/
-
-
-
WLD
6HULHV$DQG%
,1&20,1*/,1(
32:(5
6HULHV&
,1&20,1*/,1(
32:(5
WLE
7
/
7
/
7
/
7
/
7
/
7
/
&21752/
%2$5'32:(5
)$132:(5
&21752/%2$5'
32:(5
)$132:(5
WLD
FIG. 32: Wiring Diagram
333233D
23
Dimensions
Dimensions
A
-A-
B
C
D
WLD
Driver Dimensions
A width
B depth
C mounted height
D total height
24
15.30 in (0.390 m)
18.3 in (0.465 m)
18.3 in (0.465 m)
21.5 in (0.545 m)
333233D
Technical Data
Technical Data
Electric High Pressure Airless Sprayer
US
Maximum continuous cycle rate
(To prevent premature pump wear, do NOT
exceed maximum recommended speed of
fluid pump)
Weight
Operating temperature range
Input voltage
Input current
Oil capacity†
Oil specification†
Maximum force
Metric
33 cycles per minute
115 lb
52 kg
23° to 120° F
-5° to 50° C
200-240 VAC, single phase, 50/60 Hz
20A maximum
1.5 quarts
1.4 liters
Graco part number 16W645
ISO 220 silicone-free synthetic EP gear oil†
4200 lbf
18.7 kN
† The driver gear-box is shipped from the factory pre-filled with oil. Additional oil must be purchased separately.
333233D
25
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
2ULJLQDOLQVWUXFWLRQV This manual contains English. MM 333233
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision D, March 2017

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