Graco 3A6482A, APD20 Electric Driver Instructions

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Graco 3A6482A, APD20 Electric Driver Instructions | Manualzz

Instructions

APD20 Advanced

Precision Driver

3A6482A

EN

Electric driver for the supply and application of sealant and adhesive materials. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

Model 25N519

Vertical driver for E-Flo

®

SP Electric Supply Pumps

Model 25N520

Horizontal driver for EFR Electric Fixed Ratio Proportioner

Important Safety Instructions

Read all warnings and instructions in this manual and all related manuals before using the equipment. Save all instructions.

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2

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Component Identification . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power Requirements . . . . . . . . . . . . . . . . . . . . . 6

Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Install Vented Oil Cap Before Using Equipment . 8

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

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

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

Preventive Maintenance Schedule . . . . . . . . . . . 9

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

Change the Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10

Bearing Pre-Load . . . . . . . . . . . . . . . . . . . . . . . 10

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Replace Fan Assembly . . . . . . . . . . . . . . . . . . . 11

Replace Electronics Cover . . . . . . . . . . . . . . . . 12

Calibrate the Electric Driver . . . . . . . . . . . . . . . . 15

Replace Gear and Output Shaft . . . . . . . . . . . . 15

Replace the Motor Rotor and Encoder . . . . . . . 19

Update Software . . . . . . . . . . . . . . . . . . . . . . . . 22

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Vertical Electric Driver (25D519) . . . . . . . . . . . . 24

Horizontal Electric Driver (25D520) . . . . . . . . . . 24

Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . 26

Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Repair Kits and Accessories . . . . . . . . . . . . . . . . 30

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Mounting Hole Pattern . . . . . . . . . . . . . . . . . . . . . . 33

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Technical Specifications . . . . . . . . . . . . . . . . . . . . 35

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36

Related Manuals

Manuals are available at www.graco.com.

Manual in

English

3A6165

3A6586

3A6331

3A6724

Description

EFR Electric Fixed Ratio Proportioner

E-Flo

®

SP Electric Pump

E-Flo

®

SP Supply Systems

E-Flo

®

SP Software

3A6482A

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.

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.

3A6482A 3

4

Warnings

EQUIPMENT MISUSE HAZARD

WARNING

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 Sheets (SDSs) 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.

• 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.

3A6482A

Component Identification

Component Identification

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F IG . 1: Horizontal Driver (Top) and Vertical Driver (Bottom)

-

Ref.

Description

A

B

C

D

E

Cooling Fan Assembly

Gearbox Oil Sight Glass

Gearbox Oil Breather Plug

Power Disconnect Switch

Gearbox Oil Drain Plug

Ref.

Description

F

G

H

J

Communication Ports

Lift Ring

Incoming Power Connections

Output Shaft

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3A6482A 5

Installation

Installation

2.

Bring the cord to the unit. Remove four screws to separate the junction box cover (DA) and the attached power disconnect switch (D) from the junction box (DB).

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

'%

Power Requirements

The system requires a dedicated circuit protected with a circuit breaker.

Voltage

200-240 VAC

Phase

1

Hz

50/60

Current

20 A

Connect Power

1.

Cut the power cord wires to the following lengths:

• Ground wire - 6.5 in, (16.5 cm)

• Power wires - 3.0 in. (7.6 cm)

• Add ferrules as necessary

NOTE: The power cord is not supplied with the driver.

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F IG . 3: Power Disconnect Switch

3.

With the power disconnect switch (D) and the junction box cover (DA) detached from the driver, verify that the wires inside the junction box are

installed as seen in F IG . 4.

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LQ

F IG . 2: Power Cord

6

LQ

7

7

7

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F

IG

. 4: Terminal Connections

4.

Insert power cord (from step 1) through the cord grip and into the junction box.

5.

Install power wires into terminals 1L1 and 3L2. See

F IG . 4.

3A6482A

Installation

6.

Attach the ground wire to the ground terminal inside of the junction box.

8.

Replace the junction box screws. Tighten the cord grip to securely hold the power cord in the junction box.

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F

IG

. 6: Junction Box Screws and Strain Relief

Grounding

LQ

F IG . 5: Ground Wire and Ground Terminal

7.

Place the wires into the open area on either side of the disconnect block, as space permits. Reinstall the junction box cover.

NOTICE

If wires are pinched during screw installation, damage to wires will occur. Damaged wires may prevent the connected components from functioning properly.

Make sure all wires are routed correctly before installation.

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.

3A6482A 7

8

Pressure Relief Procedure

Install Vented Oil Cap Before

Using Equipment

The driver gear-box is shipped from the factory pre-filled with oil. The temporary unvented cap (CB) prevents oil leaks during shipment. This temporary cap must be replaced with the vented oil cap (CA), supplied with the equipment, before use.

Pressure Relief

Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

CB

CA

CA

CB

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.

Turn the power disconnect switch (D) to off to remove power to the electric driver.

2.

Relieve all fluid pressure. Follow the Pressure Relief

Procedure in your separate system manual.

NOTE: Turning off the electric driver does not relieve pressure in connected pumps.

Operation

Refer to your system manual for operating instructions.

NOTE: The APD20 electric driver is operated using external electronic controls.

ti 3 4 8 1 9a

F IG . 7: Unvented and Vented Oil Caps

3A6482A

Maintenance

Maintenance

NOTICE

Do not open or remove the 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.

Preventive Maintenance

Schedule

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.

Check the Oil Level

Check the oil level in the sight glass (B). The oil level should be near the halfway point of the sight glass when the sprayer is not running. If the oil is low, open the fill cap (C) and add Graco Part No. 16W645, ISO 220 silicone-free synthetic EP gear oil. Reinstall the fill cap.

NOTE: The oil capacity for vertical models is approximately 1.0-1.2 quarts (0.9-1.1 L). The oil capacity for horizontal models is 2.0-2.2 quarts (1.9-2.1

L). 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.

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F IG . 8: Sight Glass and Oil Fill Cap

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3A6482A 9

Maintenance

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 L) container under the oil drain port. Remove the oil drain plug (E). See

F IG . 8. Allow all oil to drain from the driver.

2.

Reinstall the oil drain plug (E). Torque to 18-23 ft-lb

(25-30 N•m).

3.

Open the fill cap (C) and add Graco Part 16W645,

ISO 220 silicone-free synthetic EP gear oil. Check the oil level in the sight glass (B). Fill until the oil level is near the halfway point of the sight glass. Do not overfill.

NOTE: The oil capacity for vertical models is approximately 1.0-1.2 quarts (0.9-1.1 L). The oil capacity for horizontal models is 2.0-2.2 quarts (1.9-2.1

L).

4.

Reinstall the fill cap.

Bearing Pre-Load

See F IG . 8. The bearing pre-loads (JA) are factory-set.

NOTICE

Only adjust the bearing pre-load if a gear stage has been replaced. Improper adjustment of the bearing pre-load may cause premature failure of the gear or

housing. See Replace Gear and Output Shaft , page

15.

10 3A6482A

Repair

Repair

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Replace Fan Assembly

4.

Underneath the fan shroud, disconnect the fan cable using the two lever-lock connectors.

NOTE: The replacement fan assembly kit (26B025) must be purchased separately.

Tools required:

• 3 mm hex wrench

• 6 mm hex wrench

• 15 ft-lb (20 N•m) torque wrench

• Medium (blue) thread-locking compound

1.

Relieve pressure. Perform the

Pressure Relief

Procedure , page 8.

2.

Verify that the driver power disconnect switch (D) is turned to off. Disconnect the unit from the power source.

3.

Remove the screws that attach the fan assembly to the driver. Pull up on the end farthest from the junction box. Slide the assembly toward the junction box to remove.

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F

IG

. 10: Remove Wires

5.

Remove the fan cable from the old fan assembly.

6.

Connect the fan cable to the new fan assembly using the two lever-lock connectors. Connect the red leads into one lever-lock connector. Connect the black leads into the other connector. Secure the fan cable along the inside of the fan shroud.

7.

Install the new fan assembly. To attach the new fan assembly, slide the cover tabs into the slots on the junction box side. Gently push down the far end.

Apply thread locker and install the supplied fasteners and washers. Torque to 15 ft-lb (20 N•m).

F IG . 9: Remove Fan Assembly

3A6482A

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F IG . 11: Install Fan Assembly

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11

Repair

Replace Electronics Cover

Remove Electronics Cover

Tools required:

• 3 mm hex wrench

• 6 mm hex wrench

• 15 ft-lb (20 N•m) torque wrench

1.

Relieve pressure. Perform the Pressure Relief

Procedure , page 8.

2.

Verify that the driver power disconnect switch (D) is turned to off. Disconnect the unit from the power source.

3.

Disconnect the lower from the driver. Refer to your system manual.

NOTE: You must remove the lower from the driver in order to calibrate the driver.

4.

Remove four screws. Remove the junction box cover.

5.

Loosen the cord screws on the disconnect block.

Disconnect wires from 2T1 and 4T2.

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

6.

Remove four bolts, four washers, and the junction box sleeve.

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F

IG

. 13: Junction Box Sleeve

7.

Remove six screws and washers from the electronics cover.

F IG . 12: Junction Box Cover

7

7

7

/

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F

IG

. 14: Remove Electronics Cover

12 3A6482A

8.

Carefully tilt the electronics cover down.

NOTICE

All wires must be disconnected before the cover is completely removed. To avoid damaging the wires and connections, hold the cover in place or let the cover rest on a work surface while disconnecting wires.

10. Disconnect the stroke position sensor wire.

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Repair

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F IG . 15: Tilt Electronics Cover

9.

Pull the wire connectors out. Disconnect the motor power and motor temperature wires.

F

IG

. 17: Stroke Position Sensor Wire

11. Disconnect the encoder wire.

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F IG . 16: Motor Power and Motor Temperature Wires

F IG . 18: Encoder Wire

12. Discard the electronics cover.

3A6482A 13

Repair

Install Electronics Cover

1.

Connect the encoder wire and stroke position sensor wire to the new electronics cover.

2.

Connect the motor power and motor temperature wires.

3.

Install the electronics cover and 6 screws. Torque the screws to 15 ft-lb (20 N•m).

NOTICE

If wires are pinched during screw installation, damage to wires will occur. Damaged wires may prevent the connected components from functioning properly.

Make sure all wires are routed correctly before installation.

4.

Install the junction box sleeve. Tighten the four bolts.

5.

Install the junction box cover. Tighten the four screws.

6.

Install the power leads from the electronics cover into the power disconnect switch. Install the brown lead into terminal 2T1 and the blue lead into terminal 4T2.

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7

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/

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F IG . 19: Install Wires

7.

Connect the power cord.

8.

Turn the power disconnect switch to ON.

9.

Update the electric driver software. See

Update

Software , page 22.

10.

Calibrate the Electric Driver . See page 15.

14 3A6482A

Calibrate the Electric Driver

Repair

Replace Gear and Output Shaft

1.

Perform the Pressure Relief Procedure

. See page

8.

2.

Disconnect the lower from the driver. Refer to your system manual.

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 allow the driver rod to contact the lower rod and cause incorrect calibration.

3.

Cycle power to the driver. Turn the power disconnect switch to OFF, then turn the power disconnect switch to ON.

4.

Begin calibration. Refer to your system manual for instructions.

5.

Wait for the calibration process to finish.

a.

The driver output shaft (18) will run up and down slowly over the course of several minutes.

b.

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

c.

The driver output shaft will move up and down five to six times at a faster pace.

6.

Verify that the auto-calibration process is complete before returning to normal operation.

NOTE: The system display will indicate the success or failure of the auto-calibration process.

NOTE: The replacement gear kit (26A398) and the replacement output shaft kit (26A399) must be purchased separately.

Tools required:

• 3 mm hex wrench

• 4 mm hex wrench

• 6 mm hex wrench

• 1/4 in. hex wrench

• 2 in. open-ended wrench

• 175 ft-lb (240 N•m) torque wrench

• 150 in-lb (17 N•m) torque wrench

• Medium (blue) thread-locking compound

• Grease

Remove the Fan and Gear Cover

1.

Follow steps 1-4 in

Replace Fan Assembly

, page

11.

3A6482A

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F IG . 20: Remove Fan Assembly

2.

Drain oil from the gear box. Follow steps 1 and 2 of

Change the Oil (page 10).

3.

Using a 2 in. wrench, loosen the gear jam nuts (46) on the outside of the gear cover for later removal.

See F IG . 21.

4.

Remove the eight 6 mm hex screws (24) and washers (43) from the gear cover (2).

15

Repair

5.

The gear cover is mounted on two dowels. Pull the cover straight out to remove the cover.

5.

Remove the output shaft and second stage gear at the same time.

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F IG . 21: Remove Gear Cover

Remove the First Stage Gear

Pull out the first stage gear (11).

NOTE: As necessary, push the second stage gear (10) aside to release the first stage gear.

Remove the Second Stage Gear and Output

Shaft

1.

Turn the second stage gear (10) clockwise so the output shaft (18) is as high as possible in the motor housing.

2.

Using a 2 in. wrench, loosen the output shaft bearing (19).

3.

While holding the gear in place, remove the bearing, lower bumper (31), and support washer (32) from the output shaft.

4.

To remove the output shaft, grasp the shaft while rotating the second stage gear (10) counterclockwise.

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F IG . 22: Remove Output Shaft and Gear

Replace the Rotor Shaft Seal

1.

If necessary, remove the input shaft seal (26) from the gear side of the motor housing.

2.

Install the new seal.

Replace the Bearing Race

Remove the second stage gear bearing race (10a) from the motor housing. Replace with gear bearing race with a new race from the replacement kit.

16 3A6482A

Repair

Remove the Rack Bearing

Remove the two 4 mm hex screws (16) holding the rack bearing (17) in place. To remove the bearing, slide it sideways to release the snap feature. Then slide the bearing down through the bottom of the output shaft.

F IG . 23: Remove Rack Bearing

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Install the Rack Bearing

1.

Put gear grease on the back of the rack bearing.

Slide the bearing into the motor housing until the lip on the bottom of the bearing snaps into place.

2.

Line up the holes in the rack bearing with the holes in the motor housing.

3.

Apply blue thread-locking compound to the rack bearing screws (16). Insert the screws through the motor housing holes and into the bearing. Torque to

10 in-lbs (3 N•m).

Install the Output Shaft and Second Stage

Gear

1.

Grease the threads and o-ring of the output shaft bearing (19).

2.

Apply gear oil or grease to the back of the output shaft (18). Insert the output shaft into the motor housing (1).

3.

Hold the output shaft while inserting the second stage gear (10). Line up the gears of the shaft and gear so they mesh.

4.

Turn the gear clockwise until the output shaft has risen as high as possible. Hold the gear in place.

5.

Slide the support washer (32), bumper (31), and output shaft bearing (19) onto the output shaft (18) as far as possible. Hand tighten, then torque to 175 ft-lb (240 N•m).

Install the First Stage Gear

1.

Slide the first stage gear and bearings (11) into the motor housing (1).

2.

Line up the first stage gear with the second stage gear (10) to allow the gears mesh together.

3A6482A 17

Repair

Replace the Bearing Adjuster O-Rings

1.

Remove the loosened jam nuts (46) from the outside of the gear cover.

2.

Using a 1/4 in. hex wrench, remove the gear adjusters (15, 44) from the inside of the gear cover.

3.

Remove the o-rings (37, 45). Clean the bearing adjuster threads.

4.

Put the new o-rings (37, 45) on the bearing adjusters.

5.

Grease the o-ring area of both bearing adjusters.

6.

Apply thread sealant on the threads of the adjusters.

7.

Use a 1/4 in. hex wrench to install each adjuster into the appropriate hole.

Install the Gear Cover

1.

Remove and replace the gear cover gasket (23).

Before pressing the gasket into place, grease three or four places on the gasket groove of the gear cover.

2.

Place the gear cover (2) on the motor housing.

Secure the gear cover with either 6 mm hex screws

(24) and washers (43). Torque to 15 ft-lb (20 N•m).

F

IG

. 24: Gear Cover

18

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F

IG

. 25: Install Gear Cover

3.

Torque the second stage adjuster (15) clockwise to

150 in-lbs (17 Nm). Back off several turns counterclockwise, and then torque the second stage adjuster clockwise to 100 in-lbs (11 Nm).

4.

Torque the first stage adjuster (44) clockwise to 100 in-lbs (11 Nm). Back off several turns counterclockwise, and then torque the first stage adjuster clockwise to 70 in-lbs (8 Nm).

5.

With a 2 in. open-ended wrench, screw the jam nuts into the outside of the gear cover. Torque to 40 ft-lbs

(54 Nm).

6.

Fill the gear box with oil. Follow steps 3 and 4 of

Change the Oil . See page 10.

3A6482A

Repair

Install the Fan

Follow step 6 and 7 of Replace Fan Assembly , page

11.

Replace the Shaft Bearing Assembly

NOTE: The replacement shaft bearing assembly kit

(25C164) must be purchased separately.

Tools required:

• 2 in. open-ended wrench

• 175 ft-lb (240 N•m) torque wrench

1.

Stop the pump at the bottom of its stroke. Turn the power disconnect switch to OFF.

2.

Perform the

Pressure Relief Procedure , page 8.

3.

Disconnect the lower from the driver. Refer to your system manual for instructions.

4.

Drain the oil from the driver. See steps 1-2 of

Change the Oil , page 10.

5.

Unscrew the shaft bearing assembly (19) from the

driver. See F IG . 22, page 16.

6.

Install the new shaft bearing assembly. Torque to

175 ft-lb (240 N•m).

7.

Fill the driver with oil. See steps 3-4 of

Change the

Oil , page 10.

8.

Reconnect the lower to the driver. Refer to your system manual for instructions.

9.

Turn the power disconnect switch to ON and resume operation.

Replace the Motor Rotor and

Encoder

NOTE: The replacement motor rotor kit (26C547) and the replacement encoder kit (26C548) must be purchased separately.

Tools required:

• 4 mm hex wrench

• 6 mm hex wrench

• 1/2 in. or 13 mm socket or open-ended wrench

• 0.050 in. hex wrench

• #1 phillips screwdriver

• 15-20 ft-lb (20-27 N•m) torque wrench

• 100 in-lb (11 N•m) torque wrench

• Medium (blue) thread-locking compound

• 16W645 gear oil or compatible grease

Remove the Fan and the Motor Cover

1.

Follow steps 1-4 of

Replace Fan Assembly

. See

page 11. Set aside the fan assembly.

3A6482A

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F IG . 26: Remove the Fan Assembly

2.

Use a 6 mm hex wrench to remove the four bolts

(24) and washers (43) that secure the motor cover

(4). See F IG . 27, page 20.

19

Repair

3.

Remove the motor cover (4).

Remove the Rotor

1.

Use a 6 mm wrench to remove three screws (24) and washers (43) from the rotor support (5). Be careful not to scratch any surfaces.

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F IG . 27: Remove the Motor Cover

Remove the Encoder

1.

Unplug the cable from the encoder (21).

2.

Use a 0.050 in. hex wrench to loosen the two hub set screws (21a) on the sides of the encoder. Do not remove the screws.

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F

IG

. 29: Remove the Rotor Support

D

1

Do not damage the surface.

2.

Manually pull the rotor (28) out of the stator.

NOTICE

The rotor is a very strong magnet. Keep it away from sensitive equipment such as cell phones, cameras, credit cards, and so on.

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F IG . 28: Encoder

3.

Use a phillips head screwdriver to remove the two encoder mounting screws (22).

4.

Pull the encoder off of the rotor support (5).

NOTE: If only the encoder needs to be replaced, see

Install the Encoder , page 21.

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F IG . 30: Remove the Rotor

20 3A6482A

Repair

Install the Rotor

1.

Grease the shaft of the rotor (28).

F

IG

. 31: Grease the Rotor Shaft

WLD

The rotor contains strong magnets. When inserting the rotor into the motor housing, avoid pinching your fingers between the rotor and the motor housing.

2.

Insert the rotor into the motor housing by holding the bearing. The rotor will pull itself into place due to the strength of the magnets.

NOTICE

Make sure the rotor seats properly and does not impact the motor housing or stator during insertion.

Improper rotor installation may cause gear failure or damage to the rotor.

6.

Replace the rotor support (5). Install the three screws (24) and washers (43). Torque to 15 ft-lb (20

N•m).

7.

To set the rotor, tighten the rotor adjuster to 100 in-lbs (11 N•m) in the clockwise direction. Back out several turns counterclockwise, then tighten the rotor adjuster to 15 in-lbs (1.5 N•m).

8.

Install the two locking screws (16). Torque to 30 in-lbs (3 N•m).

Install the Encoder

1.

If necessary, replace the encoder cable: a.

Follow steps 1-8 of

Remove Electronics Cover

(page 12).

b.

Disconnect both ends of the existing encoder cable. Discard the existing cable.

2.

Route the encoder cable (21c) through the lower port of the motor housing (1).

NOTE: The replacement encoder cable is supplied with the replacement encoder.

NOTE: The encoder connector is the smaller of the two connections.

3.

Remove the two 4 mm locking screws (16) that secure the rotor adjuster (8) to the rotor support (5).

Keep the rotor adjuster in place in the rotor support.

4.

Place a 1/2 in. or 13 mm socket or open-ended wrench in the outside center hole of the rotor support. Turn the wrench clockwise to loosen the position of the rotor adjuster.

5.

Place the spring disc (6) on the rotor shaft. See F IG .

32.

F

WLD

F

IG

. 32: Place Spring Disc on Rotor Shaft

3A6482A

WLD

F IG . 33: Route Encoder Cable

3.

Slide the new encoder onto the rotor shaft.

4.

Apply a small amount of medium (blue) thread locker to the two phillips head mounting screws (22).

Secure the encoder to the rotor support (5).

21

Repair

5.

Use the 0.050 in. hex wrench to remove the two set screws (21a) from the encoder hub.

6.

Apply a small amount of medium (blue) thread locker to the set screws (21a). Install the screws into the encoder.

7.

Tighten the screws by hand.

8.

Plug the encoder cable into the encoder and the control board. See

Wiring Diagram , page 31.

9.

If the electronics cover was removed, re-install the electronics cover. See

Install Electronics Cover , page 14.

10.

Install the Motor Cover . See page 22.

Install the Motor Cover

1.

Install the motor cover (4) onto the motor housing.

See F

IG

. 27, page 20.

2.

Use a 6 mm hex wrench to install the four bolts (24) and washers (43) that hold the motor cover in place.

Torque the bolts to 15 ft-lb (20 N•m).

3.

Install the fan assembly. See steps 6 and 7 of

Replace Fan Assembly , page 11.

4.

Calibrate the Electric Driver . See page 15.

5.

Re-connect the lower to the electric driver. Refer to your system manual for instructions.

Update Software

Refer to your system or system software manual for the software update procedure.

NOTE: Software updates require a Graco electronic display or control, such as an ADM (Advanced Display

Module).

22 3A6482A

Repair

3A6482A 23

Parts

Parts

Vertical Electric Driver (25D519)

Horizontal Electric Driver (25D520)

WLE

202

24 3A6482A

Ref.

Part Description

201 ----DRIVER, APD20, horizontal

----DRIVER, APD20, vertical

202

16T764 LABEL, warning

203 17X387 BOX, junction, power, motor, APD

204 117080 SCREW, socket head, m8 x 60

205 102726 PLUG, pipe headless

206 121171 GRIP, cord, 0.35-0.63, 3/4

207 123970 SWITCH, disconnect, 40 A

208 130692 COVER, junction box, APD motor

209 113768 SCREW, socket, flat head

210 130729 KNOB, disconnect, panel, black

213 116343 SCREW, ground

▲ Replacement safety labels, tags, and cards are available at no cost.

Qty.

25N519 25N520

1

1

1

1

1

1

4

1

1

4

1

4

1

4

1

1

1

4

4

1

1

1

Parts

3A6482A 25

Parts

Electrical Enclosure

WLD

E D

1

Torque to 15-20 ft-lb (20-27 N•m).

2

Apply serviceable medium (blue) thread-locker to threads.

5

Torque to 30-40 in-lb (3.4-4.5 N•m).

13

Torque to 100 in-lb (11 Nm). Back off and torque to 14-18 in-lb (1.6-2.0 N•m).

15

Lubricate with gear oil or compatible grease.

26 3A6482A

Parts

Gear Box

3A6482A

F

F

WLD

27

Parts

1

Torque to 15-20 ft-lb (20-27 N•m).

2

Apply serviceable medium (blue) thread-locker to threads.

3

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

4

After the gear train is assembled, torque both lock nuts to 40-50 ft-lb (240-280 N•m).

5

Torque to 30-40 in-lb (3.4-4.5 N•m).

11

14

After the gear cover (2) is installed, torque the adjuster (15) to 150 in-lb (17 N•m). Back off and torque to 100-120 in-lb (11-12 N•m). Then torque adjuster (44) to 100 in-lb (11 N•m). Back off and torque to 70-80 in-lb (8-9 N•m).

Torque to 100 in-lb (11 Nm). Back off and torque to

14-18 in-lb (1.6-2.0 N•m).

15

Lubricate with gear oil or compatible grease.

Ref.

1

2

★✓

3

5*

6*

8*

9

3a

3b

3c

4

10†

11†

13 ★✓

14

★✓

15 ★✓

16

17‡

18‡

19 ◆

21

22 ❖

23† ★✓

24

25

26†

28*

29

31 ◆

32

Part

-----

107100

-----

-----

-----

-----

-----

-----

109114

121319

25C182

-----

24W120

25C163

25C162

-----

-----

26B024

26B023

26C545

125856

116343

17X343

-----

-----

-----

15F931

-----

-----

15H525

24E315

Description

HOUSING, main

COVER, gear

COVER, electronics, assembly, APD20, horizontal

COVER, electronics, assembly, APD20, vertical

BOARD, communication

SCREW, 8-32, flange head

SCREW, ground

COVER, motor

SUPPORT, rotor

SPRING, disc

ADJUSTER, rotor

RING, lift, sst 1 9/16 thread

GEAR, assembly, second stage

GEAR, assembly, first stage, tapered

CAP, fill

SIGHTGLASS

ADJUSTER, bearing, second stage

SCREW, cap, socket head

BEARING, rack

RACK, assembly

BEARING, shaft, assembly

ENCODER,

SCREW, machined, pan head, 4x.25

GASKET, housing, gear

SCREW, cap, socket head

FITTING, adapter, npt x jic

SEAL, input shaft

ROTOR

SENSOR, stroke position

BUMPER, lower

WASHER, support

Qty.

25N519

1

1

25N520

1

1

1

1

24

1

1

1

2

1

1

1

1

1

1

4

1

1

1

1

1

1

1

1

1

1

1

4

4

1

1

24

1

1

1

2

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

1

1

1

4

1

1

4

28 3A6482A

Ref.

33

▲★✓

114

115

116

117

119

120

122

124

37†

★✓

43

44 ★✓

45†

★✓

46

★✓

56

61

92

93

96

97

112

Part

17Y723

17J476

-----

104572

-----

-----

-----

124165

108860

108788

26B025

127721

127463

C20987

126453

-----

130685

-----

-----

120112

-----

-----

Description

LABEL, safety, warning, horizontal

LABEL, safety, warning, vertical

PACKING, o-ring

WASHER, lock spring

ADJUSTER, 1st stage roller bearing

PACKING, o-ring

NUT, jam

SCREW, button head, m5-0.8x10, ss

SCREW, machined, pan head, phillips

WASHER, flat

COVER, fan, 24 Vdc, assembly, silver

KNOB, impact, preventer

SCREW, cap, socket head

PACKING, o-ring

POWER SUPPLY, 24 V

SCREW, machined, #8-32 x 0.375

BRACKET, 24 V supply, APD motor

HARNESS, power supply, 24 V, APD

HARNESS, power supply, 240 V, APD

FITTING, cap nut, -8 JIC

FITTING, street elbow, 3/4 npt

FITTING, elbow, street

▲ Replacement safety labels, tags, and cards are available at no cost.

* Parts included in Rotor Kit 26C547 (purchase separately).

† Parts included in Gear Kit 26A398 (purchase separately).

‡ Parts included in Output Shaft Kit 26A399 (purchase separately).

◆ Parts included in Shaft Cartridge Kit 25C164 (purchase separately).

❖ Parts included in Encoder Kit 26C548 (purchase separately).

✠ Parts included in Bolt Kit 26A537 as pack of 10 (purchase separately).

✖ Parts included in Harness Kit 18A109 (purchase separately).

★ Parts included in Gear Cover Kit 26C566 (for E-Flo SP vertical driver). Purchase separately.

✓ Parts included in Gear Cover Kit 26C567 (for EFR proportioner horizontal driver). Purchase separately.

NOTE: The driver gear box is pre-filled with oil. Additional silicone-free, ISO 220-compliant, synthetic gear oil included in 16W645 (purchase separately).

Qty.

25N519 25N520

1

2

1

1

1

1

1

4

1

1

1

1

3

1

1

2

24

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

4

2

4

1

24

1

1

Parts

3A6482A 29

Repair Kits and Accessories

Repair Kits and Accessories

Motor Part No.

All motors in this manual

25N519

25N520

Description

APD20 Drivers

Kits

26A398

26A399

25C164

26C547

26C548

26A537

18A109

26B025

26C545

16W645

Vertical Driver for E-Flo SP 26B023

26C566

Horizontal Driver for EFR

Proportioner

26B024

25C567

Kit Description

Gear kit

Output shaft kit

Shaft cartridge kit

Motor rotor kit

Motor encoder kit

Bolt kit

Power supply harness kit

Fan assembly

Communication board

ISO 220, silicone-free synthetic gear oil, 1 quart (0.95 L)

Electronics cover for E-Flo SP

Gear box cover for E-Flo SP

Electronics cover for EFR Proportioner

Gear box cover for EFR Proportioner

30 3A6482A

Wiring Diagram

Wiring Diagram

=$

=%

WLD

F IG . 34: Electric Driver Internal Wiring

Ref.

Part Description

3

21*

29

61

114

26B023 Electronics cover, vertical

26B024 Electronics cover, horizontal

----Motor encoder (includes harness)

24W120 Stroke position sensor (includes harness)

108860 Power supply ground screw

126453 24 V power supply

117† -----

119† -----

Harness, power supply, 24 V DC

Harness, power supply, 240 VAC

ZA

ZB‡

----Harness, motor leads

17E597 Fan cable

* Parts included in Encoder Kit 26C548 (purchase separately).

† Parts included in Harness Kit 18A109 (purchase separately).

‡ Part pre-assembled with electronics cover.

+

POS

3A6482A

L

N

G

GND

31

Wiring Diagram

<$

WLD

F IG . 35: Incoming Power Connections

Ref.

YA

YB

207

Description

Ground connection

Power connections

Disconnect switch

7

7

7

/

/

/

WLE

<%

32 3A6482A

Mounting Hole Pattern

) (

&

Mounting Hole Pattern

F IG . 36: Mounting Hole Pattern

Mounting Hole Dimensions

A

B

C

D

E

F

6.2 in. (157 mm)

6.2 in. (157 mm)

Four 3/8-16 mounting holes

5/8-11 tie rod holes

5.9 in. (150 mm) bolt circle

8.0 in. (203 mm) bolt circle

$

3A6482A

WLD

33

Dimensions

Dimensions

-A-

B

A

C

D

WLD

F

IG

. 37: Dimensions

Driver Dimensions

A (width)

B (depth)

C (mounted height)

D (total height, as shipped)

14.9 in (0.378 m)

18.3 in. (0.465 m)

18.3 in. (0.465 m)

21.5 in. (0.545 m)

34 3A6482A

Technical Specifications

Technical Specifications

APD20 Advanced Precision Driver

Operating temperature range

Input voltage

Maximum input current

US

23° to 120° F

Metric

-5° to 50° C

200-240 VAC, single phase, 50/60 Hz

20 A

Oil specification

Graco Part No. 16W645

ISO 220 silicone-free synthetic EP gear oil*

4840 lb 21.5 kN Maximum force

Maximum continuous cycle rate

Maximum continuous cycle rate 26 cycles per minute

To prevent premature pump wear, do not exceed the maximum recommended speed of the fluid pump.

Oil capacity*

Vertical model (25N519)

Horizontal model (25N520)

Weight

1.5 quarts

2.2 quarts

1.4 L

2.1 L

All models

Notes

115 lb 52 kg

* The driver gear box is shipped from the factory pre-filled with oil. Additional oil must be purchased separately.

All trademarks or registered trademarks are the property of their respective owners.

3A6482A 35

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.

Original instructions. This manual contains English. MM 3A6482

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2018, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision A, January 2019

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