Graco 3A5173A, Yuhong Electric Driver for High Pressure Airless Sprayers Instructions

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Graco 3A5173A, Yuhong Electric Driver for High Pressure Airless Sprayers Instructions | Manualzz

Instructions

Yuhong Electric Driver for

High Pressure Airless Sprayer

Electric driver for application of protective coatings. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

Model 25M480

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

3A5173A

EN

WLD

2

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Install Vented Oil Cap Before Using Equipment . 7

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Preventative Maintenance Schedule . . . . . . . . . . 9

Change the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Bearing Pre-Load . . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Power Saving Mode . . . . . . . . . . . . . . . . . . . . . 10

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Related Manuals

Manuals are available at www.graco.com.

Component manuals in English:

3A4809 Yuhong Electric High Pressure Sprayer Manual

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Replace Shaft Bearing Assembly . . . . . . . . . . . 13

Replace Fan Fuses . . . . . . . . . . . . . . . . . . . . . . 14

Replace Fan Assembly . . . . . . . . . . . . . . . . . . . 14

Replace Electronics Cover . . . . . . . . . . . . . . . . 16

Repair Token Cable . . . . . . . . . . . . . . . . . . . . . . 19

Software Update Procedure . . . . . . . . . . . . . . . 20

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Electric Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Parts List - Electric Driver (25M480) . . . . . . . . . 23

Mounting Hole Pattern . . . . . . . . . . . . . . . . . . . . 24

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Technical Specifications . . . . . . . . . . . . . . . . . . . . 27

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28

3A5173A

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.

ELECTRIC SHOCK HAZARD

WARNING

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.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation.

Get immediate surgical treatment.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the

Pressure Relief Procedure

when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

3A5173A 3

Warnings

4

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. 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 sparking).

• Ground all equipment in the work area. See

Grounding

instructions.

• Never spray or flush solvent at high pressure.

• 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.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are anti-static 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.

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 Specifications

in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See

Technical

Specifications

in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheet (SDS) from distributor or retailer.

• 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. 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.

3A5173A

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 F

IG

. 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.

Power Supply

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)

Gauge

12 AWG

10 AWG

6 AWG

4 AWG mm

2

3.31

5.26

13.29

21.14

2)) S

G

E

WLD

F IG . 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 terminals 1L1 and 5L3. See F IG . 3.

NOTE: Press gasket against back sealing face of junction box to ease installation of power cord.

7

7

7

/

/

/

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 F

IG

. 1.

G

LQ

WLE

C2

F IG . 3: Terminal Connections

4.

Insert power cord (from step 1) through cord grip

(C2) and into junction box (S).

NOTE: Power wires should be installed into terminals 2T1 and 6T3. See F IG . 3:

POWER

F IG . 1: Power Cord

3A5173A

LQ

WLD

GROUND

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 F

IG

. 6.

S

WLE

F IG . 4: Attach Ground Wire

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 F IG . 5.

NOTICE

If wires get pinched when the screws are tightened, damage will occur. Make sure all wires are routed correctly before installation.

WLD

F IG . 6: Junction Box Screws and Strain Relief

G

E

F IG . 5: Grounding Wire

6

J

WLD

3A5173A

Installation

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.

Driver: The driver is grounded through the power cord.

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.

P

PX ti31010a

F IG . 7: Unvented and Vented Oil Caps

NOTE: Series A models were shipped empty with only the vented oil cap (P). See

Check Oil Level , page 9, for

information on how to fill Series A models before use.

3A5173A 7

Setup

Setup

1.

Pull pressure adjustment knob (H) out and turn counterclockwise until it stops. Push the knob in to lock.

H

Operation

The motor will adjust the speed to maintain a constant fluid pressure.

1.

Pull the pressure adjustment 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 F IG . 8.

ti20171a_1

F IG . 8: Pressure Adjustment Knob

2. Turn power switch (E) OFF. Connect unit to power

source. See F IG . 2, page 5.

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.

8 3A5173A

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 F IG . 9.) The oil level should be near the halfway point of the sight glass when the sprayer is not running. If oil is low, open vented oil cap (P) and add Graco Part No. 16W645 ISO

220 silicone-free synthetic EP gear oil. See F IG . 9.

The oil capacity is approximately 1.0 - 1.2 quarts (0.9 -

1.1 liters).

Do not overfill.

NOTICE

Only use oil with Graco part number 16W645. Any other oil may not lubricate properly and can cause damage to the drive train.

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.

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.

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 vented oil 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 F IG .

9.) 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.

4.

Reinstall the vented oil cap (P).

R

K

WLE

F IG . 9: Sight Glass and Oil Fill Cap

Bearing Pre-Load

See F IG . 9. The bearing pre-loads (R) are factory set and are not user adjustable. Do not adjust the bearing pre-loads.

3A5173A 9

Troubleshooting

Troubleshooting

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.

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

Error Codes

Error codes can take two forms:

Alarm: alerts you to the alarm cause and shuts down the pump.

Deviation: alerts you to the problem, but pump may continue to run past the set limits until the system’s absolute limits are reached.

The blink code is displayed using the power status indicator light (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.

/

(

WLD

F

IG

. 10: Power Status Indicator Light

NOTE: To clear an error code, first try turning the pressure adjustment knob (H) counterclockwise until it stops. If the power status indicator light (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

1 Alarm

2 Alarm

Troubleshooting Steps

Voltage Too Low

• Verify that line voltage is within the range specified in

Technical Specifications , page 27.

Use the recommended cord (see page 5).

• Cycle power and check status indicator to see if error is still active.

Voltage Too High

• Verify that line voltage is within the range specified in

Technical Specifications , page 27.

• 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.

10 3A5173A

Troubleshooting

3

Blink Code Error Type

Deviation

4

5

6

7

8

9

10

11

12, 13

Fast Flash

Deviation

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Deviation

Troubleshooting Steps

Low Temperature

• Warm equipment.

• Contact your Graco distributor or Tech Service for more information.

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.

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.

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.

Encoder Calibration Error

• Cycle power and check status indicator to see if error is still active.

Calibrate the encoder (see page 18).

• 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.

Software Versions Do Not Match

• Obtain software update token and follow

Software Update Procedure , page 20

(contact your Graco distributor or Tech Service for more information).

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.

See Power Saving Mode

, page 10.

3A5173A 11

Troubleshooting

Problem

Driver does not turn over and LED is off

Driver does not turn over and LED is on

Oil is leaking

Encoder fault

Cause

Over voltage (greater than 300 V)

No power to control board

Oil was over-filled

Drain plug not tightened properly

Seal cartridge o-ring missing or damaged.

Solution

• Check power supply

• Contact your Graco distributor or Tech Service for more information.

• Cycle power.

• Contact your Graco distributor or Tech Service for more information.

• Drain and refill as stated in

Check Oil Level , page 9.

• Torque to 18-23 ft-lb (25-30 N•m).

• Replace shaft bearing assembly.

12 3A5173A

Repair

Repair

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 8, before performing any repair

procedure.

Replace Shaft Bearing

Assembly

1.

Stop pump at bottom of its stroke. Shut off and remove power to driver.

2.

Perform

Pressure Relief Procedure , page 8.

3.

Disconnect lower from driver. See sprayer manual.

4.

Drain oil from driver. See

Change the Oil , page 9.

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 22.

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 9.

9.

Reconnect lower to driver.

10. Turn power ON and resume operation.

NOTE: Series A drivers require a different shaft bearing assembly part number. See

Parts

, page 22, for the

correct part numbers.

3A5173A 13

Repair

Replace Fan Fuses Replace Fan Assembly

1.

Perform

Pressure Relief Procedure , page 8.

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.

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.

1.

Perform

Pressure Relief Procedure , page 8.

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). See F IG . 11.

4.

Loosen screws for 1L1 and 5L3 and gently remove wires from each location.

53

G

J

7

7

7

/

/

/

WLD

WLD

F IG . 11: 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.

NOTE: Make sure no wires get pinched during installation.

F

IG

. 12: 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 F

IG

. 12.

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

F IG . 13: Grounding Screw

14 3A5173A

Repair

7.

Loosen fan cord grip (C1) attached to driver and pull out fan wires.

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 F

IG

. 13.

WLD

F IG . 14: Remove Fan Wires

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.

WLD

F IG . 15: Fan Assembly Removal

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).

7

7

7

/

/

/

WLD

F IG . 17: Reattach Ground Wire

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 5L3. See F IG . 13.

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 F IG . 11, page 14.

NOTICE

If wires get pinched when the screws are tightened, damage will occur. Make sure all wires are routed correctly before installation.

NOTE: Make sure no wires get pinched during installation.

14. Tighten cord grip attached directly to driver assembly.

C1

WLE

F IG . 16: Fan Assembly Installation

3A5173A 15

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 8.

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 18).

4.

Remove two screws (6) and remove junction box cover (G).

7

7

7

/

/

/

7

7

7

/

/

/

WLE

F IG . 20: Disconnect Fan Wires

8.

Use an adjustable wrench to loosen the fan cord grip (C1).

51

G

6

WLE

F IG . 18: Junction Box Cover

5.

Loosen cord screws on disconnect block (51) and disconnect wires from locations 1L1 and 5L3.

NOTE: Power cord cables (excluding the ground wire) may remain attached.

6.

Unscrew ground screws from fan and power cord ground wires.

C1

WLD

F IG . 21: 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 (101).

52

101

56

WLD

F IG . 19: Ground Screw Location

16

F IG . 22: Junction Box Sleeve

WLD

3A5173A

11. Remove 12 screws (20) and washers from electronics cover (50).

50

20

Repair

14. Disconnect the stroke position sensor wire (W).

W

WLD

F IG . 23: Electronics Cover Removal

12. Carefully tilt electronics cover (50) down.

F IG . 26: Stroke Position Wire

15. Disconnect the encoder wire (U).

WLD

50

F IG . 24: Tilt Electronics Cover

WLD

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.

13. Pull wire connectors down, out of the harness clip and disconnect the motor power and motor temperature wires (M).

53

U

WLD

F IG . 27: Encoder Wire

16. Discard the used cover gasket (53) and the junction box gasket (52).

M

WL[[[[D

F IG . 25: Motor Wires

WLD

52

WLD

F IG . 28: Electronics Cover and Junction Box Gaskets

3A5173A 17

Repair

Installation

1.

Install the new cover gasket (included in the

electronics cover kit). See F

IG

. 28, page 17.

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 F

IG

. 23, page 17.

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.

7

7

7

/

/

/

WLD

F IG . 29: Install Fan Wires

7.

Connect fan ground wire. See F IG . 22, page 16.

See F IG . 19, page 16.

8.

Use an adjustable wrench to tighten the fan cord

grip (C1). See F IG . 21, page 16.

9.

Install gasket (52), junction box sleeve (101), and

tighten four bolts (56). See F IG . 22, page 16.

10. Install junction box cover (G) and tighten two screws

(6). See F

IG

. 18, page 16.

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.

Calibration

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 (E) to OFF, and then to ON again.

2. Wait for the power status indicator (L) to turn on solid or start blinking.

3. Within 30 seconds, rapidly turn the pressure adjustment knob (H) back and forth from 0 to 10 at least five times and then set the knob back to 0. If the power status indicator (L) was solid before, it will begin blinking an encoder calibration error (code 8) during the calibration process.

4. The driver output shaft (V) will run up and down slowly over the course of several minutes.

5.

Midway through the auto-calibration process, the driver output shaft (V) will pause as it moves to the next step.

6. The driver output shaft (V) will move up and down faster 5-6 times.

7.

Ensure the auto-calibration process is complete before continuing. Wait for the LED to stop blinking.

18 3A5173A

Repair

Repair Token Cable

1.

Perform

Pressure Relief Procedure , page 8.

2.

Disconnect unit from power source.

3.

Remove 12 screws (20) and washers from

electronics cover (50). See F IG . 23, page 17.

4.

Carefully tilt electronics cover (50) down.

See F IG . 24, page 17.

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).

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.

WLD

F IG . 30: Token Wire

T

3A5173A 19

Repair

Software Update Procedure

1.

Perform

Pressure Relief Procedure , page 8.

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).

7. The red power status indicator light (L) will flash while the software is being loaded (approximately

30 seconds). When the software is completely loaded, the light will turn off for four seconds before the software version flashes. Then a solid light will stay on.

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

TS

L

WLD

F IG . 31: 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.

F IG . 32: Red Indicator Light Location

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.

20 3A5173A

Repair

3A5173A 21

Parts

Parts

Electric Driver

F IG . 33: Electric Driver Parts

22

101

3

D

E

F

WLG

3A5173A

Parts

Parts List - Electric Driver (25M480)

Ref.

Part Description

1 CHASSIS

2 15H392 ADAPTER, rod Xtreme

5† 17B507 COVER, junction box

6† 115264 SCREW, cap, socket head

7† 104572 WASHER, lock spring

8*† 17B509 GASKET, cover, junction box

9 15H525 CAP, fill

10 TAG, oil

11 555448 PLUG, stl, 3/8 pipe hex

12 123971 KNOB, disconnect, operator

13 121171 GRIP, cord, .35-.63, 3/4

14 25C164 CARTRIDGE, output seal

14a 25C162 KIT, washer, support

14b 25C163 KIT, bumper, lower

14c 25C165 ORING (pack of two)

15 15H432 PLUG, oil drain

16 24E315 SIGHT GLASS

17

16W360 LABEL, safety, warning

18 15F931 RING, lift, sst

19

16T764 LABEL, warning

20*‡ 109114 SCREW, cap, sch

21*‡ 104572 WASHER, lock, spring

22 24V224 COVER, fan, assy

(includes fan, cable and fasteners)

23* 16U113 KNOB KIT

50* ELECTRONICS COVER

51 262657 SWITCH, power, 40A

52 16Y458 GASKET, junction box

53* 16Y460 GASKET, side cover

55 108788 WASHER, flat

56 124165 SCREW, cap, socket head

69 LABEL, branding, Xtreme Z45

LABEL, branding, Xtreme Z25

96 127721 KNOB, impact control, preventer

Qty.

1

1

1

1

1

1

2

1

1

1

1

2

2

1

1

1

1

31

1

1

28

1

1

1

1

1

1

1

1

1

1

1

Ref.

Part Description

97 127463 SCREW, cap, socket head

101‡ 17B505 SLEEVE, junction box

102 17B553 ERROR CODE LABEL

16Y491 TOKEN CABLE (not shown)

104 16W645 GEAR LUBE

116682 FUSE (not shown)

24W120 SENSOR, stroke position

105

195792 LABEL, warning

* 24W078 KIT, electronics, cover

(includes 8, (12x) 20, (12x) 21, 23, 50, 53, and ferrules)

Qty.

1

1

1

0

1

1

1

1

† 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 Specifications:

Ref.

1

Instruction

Torque to 20 - 27 N•m (15-20 ft-lb)

3

Torque to 240 -280 N•m (175-200 ft-lb)

4

5

Torque to 25-30 N•m (18-23 ft-lb)

Torque to 195-210 N•m (145-155 ft-lb). Apply serviceable medium thread locker.

3A5173A 23

Parts

Mounting Hole Pattern

' &

%

$ WLD

F IG . 34: Mounting Hole Pattern

A B C D

6.186 in. (157 mm) 6.186 in. (157 mm) Four 3/8-16 Mounting Holes 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

24 3A5173A

Wiring Diagram

Wiring Diagram

$,5)/2:',5(&7,21

-

72/

72/

,1&20,1*/,1(

32:(5

7

7

7

/

/

/

WLE

-

-

&21752/%2$5'

32:(5

)$132:(5

WLE

F IG . 35: Wiring Diagram

3A5173A

WLD

25

Dimensions

Dimensions

WLD

F IG . 36

Driver Dimensions

A width

B depth

C mounted height

D total height

15.30 in (0.390 m)

18.3 in (0.465 m)

18.3 in (0.465 m)

21.5 in (0.545 m)

26

-A-

B

A

C

D

3A5173A

Technical Specifications

Technical Specifications

Yuhong Electric High Pressure Airless Sprayer

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

US

33 cycles per minute

Metric

115 lb

23° to 120° F

52 kg

-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.

3A5173A 27

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 3A5173

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 A, October 2017

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