Graco 3A2526H E-Flo DC Motor Instructions

Instructions-Parts
E-Flo® DC Motor
Electric drive for low to medium volume paint circulation pumps.
For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 3 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.
3A2526H
EN
Contents
Models...............................................................
Basic Models ...............................................
Basic Models with Region-Specific
Approvals.......................................
Advanced Models ........................................
Advanced Models with Region-Specific
Approvals.......................................
3
3
4
5
6
Warnings ........................................................... 7
Installation.......................................................... 10
Fill With Oil Before Using Equipment ............. 10
Power Supply Requirements......................... 10
Connect the Power Supply ........................... 11
Grounding ................................................... 12
Intrinsically Safe Installation Requirements
for Advanced Motors....................... 12
Control Board Replacement Kits 24U934,
24U936, 24U935, 24U937 ..................... 27
Overview ..................................................... 27
Tools Required ............................................ 27
Replacement Instructions ............................. 27
Encoder Replacement Kit 24U938 ....................... 30
Overview ..................................................... 30
Tools Required ............................................ 30
Replacement Instructions ............................. 30
Position Sensor Replacement Kit 16U705 ............ 33
Overview ..................................................... 33
Tools Required ............................................ 33
Replacement Instructions ............................. 33
Error Code Troubleshooting ................................ 17
Advanced Power Board Replacement Kit
24U939 ................................................ 35
Tools Required ............................................ 35
Replacement Instructions ............................. 35
Prepare Motor.............................................. 35
Disconnect Power Wires............................... 35
Remove Control Module Bracket................... 35
Remove Electronics Cover ........................... 36
Disconnect Power Barrier Board ................... 36
Install New Power Barrier Board ................... 37
Reinstall Electronics Cover ........................... 37
Reinstall Wiring Box Cover ........................... 37
Attach Control Module Bracket...................... 38
Power Unit................................................... 38
Reattach Pump Lower .................................. 38
Repair................................................................ 19
Replace Output Seal Cartridge ..................... 19
Appendix A - System Control Drawing
24N637 ................................................ 39
Parts.................................................................. 20
Basic Motor Assembly .................................. 20
Advanced Motor Assembly ........................... 22
Mounting Hole Pattern ........................................ 44
Operation ........................................................... 13
Startup ........................................................ 13
Shutdown .................................................... 13
Pressure Relief Procedure............................ 13
Advanced Motor Operation ........................... 13
Basic Motor Operation.................................. 14
Maintenance ...................................................... 16
Preventive Maintenance Schedule ................ 16
Change the Oil............................................. 16
Check Oil Level ........................................... 16
Bearing Pre-Load......................................... 16
Notes ................................................................ 24
Technical Data ................................................... 45
Graco Standard Warranty.................................... 46
Repair Kits, Related Manuals, and
Accessories .......................................... 25
2
3A2526H
Models
Models
Basic Models
Motor Part No.
Series
Horsepower
Maximum Force, lbf (N)
EM0011
C
1
1400 (6227)
EM0021
C
2
2800 (12455)
0359
II 2 G
Ex db IIA T6 0°C≤Ta≤40°C
FM12ATEX0067X
IECEx FMG 12.0028X
For Class I, Div. 1, Group D T6.
Class 1, Zone 1, AEx db IIA T6 0°C≤Ta≤40°C
Ex d IIA T6 Gb 0°C≤Ta≤40°C
Figure 1 Basic Motor Identification Label
List of Standards
• IEC 60079–0: 2011 (Ed. 6)
• CSA C22.2 No. 0.4:2004 (R2009)
• IEC 60079–1: 2007 w/Corr 1 (Ed 6)
• CSA C22.2 No. 0.5:82 (R2008)
• EN 60079–0: 2012
• CSA C22.2 No. 30:M86 (R2007)
• EN 60079–1: 2007
• CAN/CSA-E60079–0:2011
• ANSI/ISA 60079–0: 2009
• CAN/CSA-E60079–1:2011
• ANSI/ISA 60079–1: 2009
• CAN/CSA C22.2 No. 1010.1:2004
• FM 3615:2006
Specific Conditions of Use:
1. Consult the manufacturer if dimensional
information on the flameproof joint is necessary.
2. Consult the manufacturer for genuine
replacement fasteners. M8 x 30 socket-head
3A2526H
cap screws of Class 12.9 steel or better with a
minimum yield strength of 1100 MPa (160,000
psi) are acceptable alternatives.
3
Models
Basic Models with Region-Specific Approvals
Motor Part No.
Series
Horsepower
Maximum Force, lbf (N)
EM0013
C
1
1400 (6227)
EM0023
C
2
2800 (12455)
0359
II 2 G
Ex d IIA T6 0°C≤Ta≤40°C
FM12ATEX0067X
IECEx FMG 12.0028X
Figure 2 Basic Motor with Region-Specific Approvals
Identification Label
List of Standards
• IEC 60079–0: 2011 (Ed. 6)
• EN 60079–0: 2012
• IEC 60079–1: 2007 w/Corr 1 (Ed 6)
• EN 60079–1: 2007
Specific Conditions of Use:
1. Consult the manufacturer if dimensional
information on the flameproof joint is necessary.
2. Consult the manufacturer for genuine
replacement fasteners. M8 x 30 socket-head
4
cap screws of Class 12.9 steel or better with a
minimum yield strength of 1100 MPa (160,000
psi) are acceptable alternatives.
3A2526H
Models
Advanced Models
Motor Part No.
Series
Horsepower
Maximum Force, lbf (N)
EM0012
C
1
1400 (6227)
EM0015
C
1
1400 (6227)
EM0022
C
2
2800 (12455)
EM0025
C
2
2800 (12455)
0359
II 2 (1) G
Ex db [ia] IIA T6 0°C≤Ta≤40°C
FM12ATEX0067X
IECEx FMG 12.0028X
For Class I, Div. 1, Group D T6.
Class 1, Zone 1, AEx db [ia] IIA T6 0°C≤Ta≤40°C
Ex db [ia] IIA T6 0°C≤Ta≤40°C
Figure 3 Advanced Motor Identification Label
List of Standards
• IEC 60079–0: 2011 (Ed. 6)
• CSA C22.2 No. 0.5:82 (R2008)
• IEC 60079–1: 2007 w/Corr 1 (Ed. 6)
• CSA C22.2 No. 30:M86 (R2007)
• IEC 60079–11: 2011 (Ed. 6)
• CSA C22.2 No. 157–92 (R2006)
• EN 60079–0: 2012
• EN 60079–1: 2007
• EN 60079–11: 2012
• FM 3600:2011
• FM 3610:2010
• CAN/CSA-E60079–0:2011
• CAN/CSA-E60079–1:2011
• CAN/CSA C22.2 No. 1010.1:2004
• CAN/CSA-E60079–11:2011
• FM 3615:2006
• ANSI/ISA 60079–0:2009
• FM 3810:2005
• ANSI/ISA 60079–1:2009
• CSA C22.2 No. 0.4:2004 (R2009)
• ANSI/ISA 60079–11:2011
Specific Conditions of Use:
1. Consult the manufacturer if dimensional
information on the flameproof joint is necessary.
2. Consult the manufacturer for genuine
replacement fasteners. M8 x 30 socket-head
3A2526H
cap screws of Class 12.9 steel or better with a
minimum yield strength of 1100 MPa (160,000
psi) are acceptable alternatives.
5
Models
Advanced Models with Region-Specific Approvals
Motor Part No.
Series
Horsepower
Maximum Force, lbf (N)
EM0014
C
1
1400 (6227)
EM0016
C
1
1400 (6227)
EM0024
C
2
2800 (12455)
EM0026
C
2
2800 (12455)
0359
II 2 (1) G
Ex d [ia] IIA T6 0°C≤Ta≤40°C
FM12ATEX0067X
IECEx FMG 12.0028X
Figure 4 Advanced Motor with Region-Specific
Approvals Identification Label
List of Standards
• IEC 60079–0: 2011 (Ed. 6)
• EN 60079–0: 2012
• IEC 60079–1: 2007 w/Corr 1 (Ed. 6)
• EN 60079–1: 2007
• IEC 60079–11: 2011 (Ed. 6)
• EN 60079–11: 2012
Specific Conditions of Use:
1. Consult the manufacturer if dimensional
information on the flameproof joint is necessary.
2. Consult the manufacturer for genuine
replacement fasteners. M8 x 30 socket-head
6
cap screws of Class 12.9 steel or better with a
minimum yield strength of 1100 MPa (160,000
psi) are acceptable alternatives.
3A2526H
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
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.
Static charge may build up on plastic parts during cleaning and could discharge and ignite
flammable vapors. To help prevent fire and explosion:
• Clean plastic parts only in well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment work area.
SPECIAL CONDITIONS FOR SAFE USE
• To prevent the risk of electrostatic sparking, the equipment’s non-metallic parts should be
cleaned only with a damp cloth.
• The aluminum housing may spark upon impact or contact with moving parts, which may
cause fire or explosion. Take precautions to avoid such impact or contact.
• All flameproof joints are critical to the integrity of the motor as approved for hazardous
locations and are not repairable if damaged. Damaged parts must be replaced only with
genuine Graco parts with no substitutions.
3A2526H
7
Warnings
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.
INTRINSIC SAFETY
Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe
equipment will create a hazardous condition and can cause fire, explosion, or electric shock.
Follow local regulations and the following safety requirements.
• Be sure your installation complies with national, state, and local codes for the installation of
electrical apparatus in a Class I, Group D, Division 1 Hazardous Location, including all of the
local safety fire codes, NFPA 33, NEC 500 and 516, and OSHA 1910.107.
• Equipment that comes in contact with the equipment’s intrinsically safe terminals must
meet the entity parameter requirements specified in Control Drawing 24N637. See
Intrinsically Safe Installation Requirements for Advanced Motors, page 12. This includes
safety barriers, DC voltage meters, ohmmeters, cables, and connections. Remove the unit
from the hazardous area when troubleshooting.
• Do not install any equipment approved only for a non-hazardous location in a hazardous
area, as defined in Article 500 of the National Electrical Code (USA) or your local electrical
code. See the ID label for the intrinsic safety rating for your equipment.
• Ground the motor. Use a 12 gauge minimum ground wire, connected to a true earth ground.
See Grounding, page 12.
• Do not operate the motor with any cover removed.
• Do not substitute system components, as this may impair intrinsic safety.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
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.
8
3A2526H
Warnings
WARNING
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin
and cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before
cleaning, checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
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 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.
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.
3A2526H
9
Installation
Installation
Power Supply Requirements
Installation of this equipment involves potentially
hazardous procedures. Only trained and qualified
personnel who have read and who understand
the information in this manual should install this
equipment.
NOTE: To install an advanced motor, also see
Intrinsically Safe Installation Requirements for
Advanced Motors, page 12.
Fill With Oil Before Using Equipment
Before using the equipment, open the fill cap (P) and
add Graco Part No. 16W645 ISO 220 silicone-free
synthetic gear oil. Check the oil level in the sight glass
(K). Fill until the oil level is near the halfway point of
the sight glass. The oil capacity is approximately 1.5
quarts (1.4 liters). Do not overfill.
NOTE: Two 1 quart (0.95 liter) bottles of oil are
supplied with the equipment.
Improper wiring may cause electric shock or other
serious injury if work is not performed properly.
Have a qualified electrician perform any electrical
work. Be sure your installation complies with all
National, State and Local safety and fire codes.
See Table 1 for power supply requirements. The
system requires a dedicated circuit protected with a
circuit breaker.
Table 1 . Power Supply Specifications
Model*
Voltage
Phase
Hz
kVA
EM001x
100–130
/200–240
Vac
1
50/60
1.4
EM002x
200–240
Vac
1
50/60
2.9
* The last digit of the Model No. varies. See the
Models tables on pages 3–6.
Hazardous Area Cabling and Conduit
Requirements
Explosion Proof
All electrical wiring in the hazardous area must be
encased in Class I, Division I, Group D approved
explosion-proof conduit. Follow all National, State,
and Local electric codes.
A conduit seal (D) is required within 18 in. (457 mm)
of the motor for the US and Canada.
All cables must be rated at 70°C.
Figure 5 Sightglass and Oil Fill Cap
Flame Proof (ATEX)
Use appropriate conduit, connectors, and cable
glands rated for ATEX II 2 G. Follow all National,
State, and Local electric codes.
All cable glands and cables must be rated at 70°C.
10
3A2526H
Installation
Connect the Power Supply
Improper wiring may cause electric shock or other
serious injury if work is not performed properly.
Have a qualified electrician perform any electrical
work. Be sure your installation complies with all
National, State and Local safety and fire codes.
4. Bring the power wires into the electrical
compartment through the 3/4–14 npt(f) inlet port.
Connect the wires to the terminals, as shown.
Torque the terminal nuts to 25 in-lb (2.8 N•m)
maximum. Do not over-torque.
5. Close the electrical compartment. Torque the
cover screws (J) to 15 ft-lb (20.3 N•m).
1. Ensure that the fused safety switch (B) is shut
off and locked out.
Figure 7 Connect the Power Wires
Notes for Fig. 7
Figure 6 Locked Out Fused Safety Switch
2. Install a start/stop control (C) in the electrical
supply line (A), within easy reach of the
equipment. The start/stop control must be
approved for use in hazardous locations.
3. Open the electrical compartment (S) on the
motor.
3A2526H
1
2
3
Tighten all terminal nuts to 25 in-lb (2.8 N•m)
maximum. Do not over-torque.
Tighten cover screws to 15 ft-lb (20.3 N•m).
A conduit seal (D) is required within 18
in. (457 mm) of the motor for the US and
Canada.
11
Installation
Grounding
This 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.
NOTE: For advanced motors EM0012 and
EM0022, all motors must be bonded to the
same high integrity equipotential system. See
Intrinsically Safe Installation Requirements for
Advanced Motors, page 12.
Loosen the ground screw and attach a ground wire
(Y). Tighten the ground screw securely. Connect the
other end of the ground wire to a true earth ground.
Intrinsically Safe Installation
Requirements for Advanced Motors
Do not substitute or modify system components
as this may impair intrinsic safety. For installation,
maintenance, or operation instructions, read
instruction manuals. Do not install equipment
approved only for non-hazardous location in a
hazardous location. See the identification label for
the intrinsic safety rating for your model.
See Appendix A - System Control Drawing 24N637,
page 39, for installation requirements and entity
parameters. Follow all installation instructions in your
system manual.
Figure 8 Ground Wire
12
3A2526H
Operation
Operation
Startup
Pressure Relief Procedure
1. Unlock the fused safety switch (B) and turn it on.
See Connect the Power Supply, page 11
2. Press the start pushbutton (C).
3. Check that the power indicator (L) is lit (steady
on).
4. See Advanced Motor Operation, page 13 or
Basic Motor Operation, page 14 for further
instructions.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from splashing fluid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing the
equipment.
1. Disengage the start/stop control (C). See
Connect the Power Supply, page 11
2. Shut off and lock out the fused safety switch (B).
3. Relieve all fluid pressure as explained in your
separate E-Flo DC pump manual.
Advanced Motor Operation
Figure 9 Power Indicator
Shutdown
Follow the Pressure Relief Procedure, page 13.
The Advanced E-Flo DC motors require installation of
the 24P822 Control Module Accessory Kit to provide
the interface for users to enter selections and view
information related to setup and operation. See the
Control Module Accessory Kit manual for installation
and operation information.
NOTICE
To prevent damage to the softkey buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
Figure 10 Control Module Accessory
3A2526H
13
Operation
Basic Motor Operation
The basic motor has three operating modes:
• Pressure Mode
Pressure Mode with Integrated Runaway
Protection
Protection
In pressure mode with integrated runaway protection,
the motor will adjust the speed to maintain a constant
fluid pressure, but will shut down if it exceeds a
user-set speed.
• Flow Mode
1. Turn the Control Knob (N) fully counterclockwise
to 0.
NOTE: Before changing from one mode to another,
turn the Control Knob (N) fully counterclockwise to 0.
2. Pull the Mode Select switch (M) out to set. In
• Pressure Mode with Integrated Runaway
Pressure Mode
When in pressure mode, the motor will adjust the
speed to maintain a constant fluid pressure.
1. Turn the Control Knob (N) fully counterclockwise
to 0.
2. Pull the Mode Select switch (M) out to set. Turn
the switch to Pressure
to lock.
. Push the switch in
3. Pull the Control Knob (N) out to set. Turn the
knob clockwise to increase the pressure, or
counterclockwise to decrease the pressure.
Push the knob in to lock.
the Runaway
range, turn the switch to the
desired shutdown speed in cycles per minute (5,
10, 15, 20, or 25). Push the switch in to lock.
3. Pull the Control Knob (N) out to set. Turn the
knob clockwise to increase the pressure, or
counterclockwise to decrease the pressure.
Push the knob in to lock.
NOTE: The motor will shut down if the selected
speed is exceeded for 5 cycles. To reset, turn the
Control Knob (N) fully counterclockwise to 0, then
turn to the desired pressure.
Figure 12 Pressure Mode with Integrated Runaway
Protection
Figure 11 Pressure Mode
14
3A2526H
Operation
Flow Mode
When in flow mode, the motor will maintain a
constant speed regardless of the fluid pressure, up
to the pump’s maximum working pressure. See
Technical Data, page 45.
1. Turn the Control Knob (N) fully counterclockwise
to 0.
2. Pull the Mode Select switch (M) out to set. Turn
the switch to Flow
lock.
. Push the switch in to
3. The amount of flow is determined by the cycle
rate set with the Control Knob (N). The knob’s
scale (0–10) corresponds to a cycle adjustment
range of 0-30 cycles per minute. Turn the Control
Knob (N) clockwise to increase the cycle rate
(flow), or counterclockwise to decrease the cycle
rate (flow).
3A2526H
Figure 13 Flow Mode
15
Maintenance
Maintenance
Preventive Maintenance Schedule
Check Oil Level
The operating conditions of your particular system
determine how often maintenance is required.
Establish a preventive 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 in the sight glass (K). The oil
level should be near the halfway point of the sight
glass when the unit is not running. If low, open the
fill cap (P) and add Graco Part No. 16W645 ISO 220
silicone-free synthetic gear oil as required. The oil
capacity is approximately 1.5 quarts (1.4 liters). Do
not overfill.
Change the Oil
NOTE: Change the oil after a break-in period of
200,000–300,000 cycles. After the break-in period,
change the oil once a year. Order two Part No.
16W645 ISO 220 silicone-free synthetic gear oil.
1. Place a minimum 2 quart (1.9 liter) container
under the oil drain port. Remove the oil drain
plug (25). Allow all oil to drain from the motor.
2. Reinstall the oil drain plug (25). Torque to 25–30
ft-lb (34–40 N•m).
3. Open the fill cap (P) and add Graco Part No.
16W645 ISO 220 silicone-free synthetic gear
oil. Check the oil level in the sight glass (K). Fill
until the oil level is near the halfway point of the
sight glass. The oil capacity is approximately 1.5
quarts (1.4 liters). Do not overfill.
Figure 15 Sightglass and Oil Fill Cap
4. Reinstall the fill cap.
Bearing Pre-Load
The bearing pre-loads (R) are factory set and are not
user adjustable. Do not adjust the bearing pre-loads.
Figure 14 Oil Drain Plug
16
3A2526H
Error Code Troubleshooting
Error Code Troubleshooting
Error codes can take three 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.
• Advisory: information only. Pump will continue to
operate.
NOTE: On Advanced motors, flow (K codes) and
pressure (P codes) can be designated as alarms
or deviations. See Setup Screen 4 in the Control
Module Manual.
NOTE: In the error codes listed below, an “X” means
the code is associated with the display only.
NOTE: In the error codes listed below, a “?” in the
code is a placeholder for the unit number where the
event occurred.
NOTE: The blink code is displayed using the power
indicator on the motor. The blink code given below
indicates the sequence. For example, blink code 1–2
indicates 1 blink, then 2 blinks; the sequence then
repeats.
NOTE: A blink code of 9 is not an error code, but
an indicator of which pump is active (
softkey
has been pushed, see Run Screen 1 in the Control
Module Manual).
Applicable
Motor
Blink Code
Display Code
Alarm or
Deviation
Description
Advanced
1–2
K1D?
Alarm
Flow is below minimum limit.
Advanced
None
K2D?
Deviation
Flow is below minimum limit.
Basic and
Advanced
1
K4D?
Alarm
Flow exceeds maximum target; also
indicates pump runaway condition exists.
Advanced
None
K3D?
Deviation
Flow exceeds maximum target; also
indicates pump runaway condition exists.
Advanced
1–3
P1I?
Alarm
Pressure is below minimum limit.
Advanced
None
P2I?
Deviation
Pressure is below minimum limit.
Advanced
1–4
P4I?
Alarm
Pressure exceeds maximum target.
Advanced
None
P3I?
Deviation
Pressure exceeds maximum target.
Basic and
Advanced
2
V1I?
Alarm
Brown out; voltage supplied to motor is too
low.
Basic and
Advanced
3
V4I?
Alarm
Voltage supplied to motor is too high.
Advanced
2–3
CAD?
Alarm
Unit detects a loss of CAN communication.
This alarm is only logged. No flashing
alarm appears on the display, but the blink
code does occur.
Advanced
None
CAC?
Alarm
Display detects a loss of CAN
communication. Flashing alarm
appears on the display, and the blink code
occurs.
CONTINUED ON THE NEXT PAGE.
3A2526H
17
Error Code Troubleshooting
Applicable
Motor
Blink Code
Display Code
Alarm or
Deviation
Description
Advanced
2–4
CAG?
Alarm
Display detects a loss of modbus
communication when control access is set
to modbus.
Basic and
Advanced
4
WXD?
Alarm
An internal control board hardware failure
is detected.
Advanced
1–5
WSD?
Alarm
Invalid lower size; occurs if the unit is
operated before setting up the lower size.
Basic and
Advanced
5
T3D?
Deviation
Over temperature.
Advanced
None
P5DX
Deviation
More than one pump is assigned to a
transducer. The assignment for that
transducer is automatically cleared under
this condition. User must reassign.
Advanced
None
P6CA or
P6CB
Deviation
For units without closed loop pressure
control: Transducer (A or B) is enabled
but not detected.
Advanced
1–6
P6D?
Alarm
Advanced
None
MND?
Advisory
Basic
6
None
Alarm
For units with closed loop pressure control:
Transducer is enabled but not detected.
Maintenance counter is enabled and
countdown reached zero (0).
The Mode Select knob is set between
and Flow
Pressure
to the desired mode.
18
. Set knob
Basic and
Advanced
2–6
V1M?
Alarm
AC power is lost.
Basic and
Advanced
3–5
T2D?
Alarm
Internal thermistor disconnected.
Basic and
Advanced
3–4
WNC?
Alarm
Software versions do not match.
Basic and
Advanced
3–6
CCN?
Alarm
Circuit board communication failure.
Basic and
Advanced
4–5
WMC?
Alarm
Internal software error.
Basic and
Advanced
9
None
None
A blink code of 9 is not an error code, but
an indicator of which pump is active (see
NOTE above).
3A2526H
Repair
Repair
Replace Output Seal Cartridge
4. Drain the oil from the motor. See
Change the Oil, page 16.
5. Reinstall the oil drain plug. Torque to 25–30 ft-lb
(34–40 N•m).
1. Stop the pump at the bottom of its stroke. Shut
off and lock out power to the motor.
2. Follow the Pressure Relief Procedure, page 13.
3. Disconnect the lower from the motor, as
explained in your separate E-Flo DC pump
manual.
3A2526H
6. Unscrew the output cartridge (19) from the motor.
See Parts, page 20.
7. Install the new output cartridge. Torque to 70–80
ft-lb (95–108 N•m).
8. Fill with oil. See Change the Oil, page 16.
9. Reconnect the lower to the motor.
10. Turn on power and resume operation.
19
Parts
Parts
Basic Motor Assembly
EM0011, Series C, 1 Horsepower Motor
EM0013, Series C, 1 Horsepower Motor, with Region-Specific Approvals
EM0021, Series C, 2 Horsepower Motor
EM0023, Series C, 2 Horsepower Motor, with Region-Specific Approvals
20
3A2526H
Parts
EM0011, Series C, 1 Horsepower Motor
EM0013, Series C, 1 Horsepower Motor, with Region-Specific Approvals
EM0021, Series C, 2 Horsepower Motor
EM0023, Series C, 2 Horsepower Motor, with Region-Specific Approvals
Description
Qty
1
Part
———
HOUSING, motor
1
3
116343
3
9
15F931
SCREW, ground; M5
x 0.8
RING, lift
13
15H525
CAP, oil fill
1
14
24E315
SIGHT GLASS
1
19
24K341
1
24
———
25
27
15H432
———
CARTRIDGE, output
seal
SCREW, cap, socket
head; M8 x 1.25; 30
mm
PLUG, oil drain
1
33▲
16M130
COVER, electrical
compartment
LABEL, warning
(EM0011 and
EM0021)
Ref
1
Part
Description
Qty
16W360
LABEL, warning
(EM0013 and
EM0023)
LABEL, warning
1
KIT, knob; kit
includes replacement
parts for one knob
OIL, gear, synthetic;
ISO 220 silicone-free;
1 quart (0.95 liter);
not shown
WASHER, lock,
spring; no. 8
2
34▲
196548
36
16U113
38
16W645
43
———
4
1
1
2
4
1
▲ Replacement Danger and Warning labels, tags,
and cards are available at no cost.
3A2526H
Ref
Items marked — — — are not available separately.
21
Parts
Advanced Motor Assembly
EM0012, Series C, 1 Horsepower Motor
EM0014, Series C, 1 Horsepower Motor, with Region-Specific Approvals
EM0015, Series C, 1 Horsepower Motor
EM0016, Series C, 1 Horsepower Motor, with Region-Specific Approvals
EM0022, Series C, 2 Horsepower Motor
EM0024, Series C, 2 Horsepower Motor, with Region-Specific Approvals
EM0025, Series C, 2 Horsepower Motor
EM0026, Series C, 2 Horsepower Motor, with Region-Specific Approvals
22
3A2526H
Parts
EM0012, Series C, 1 Horsepower Motor
EM0014, Series C, 1 Horsepower Motor, with Region-Specific Approvals
EM0015, Series C, 1 Horsepower Motor
EM0016, Series C, 1 Horsepower Motor, with Region-Specific Approvals
EM0022, Series C, 2 Horsepower Motor
EM0024, Series C, 2 Horsepower Motor, with Region-Specific Approvals
EM0025, Series C, 2 Horsepower Motor
EM0026, Series C, 2 Horsepower Motor, with Region-Specific Approvals
Description
Qty
Ref
Part
Description
Qty
1
Part
———
HOUSING, motor
1
33▲
16M130
1
3
116343
3
9
15F931
SCREW, ground; M5
x 0.8
RING, lift
13
15H525
CAP, oil fill
1
14
24E315
SIGHT GLASS
1
19
24K341
1
———
25
15H432
———
COVER, electrical
compartment
1
OIL, gear, synthetic;
ISO 220 silicone-free;
1 quart (0.95 liter);
not shown
WASHER, lock,
spring; no. 8
2
24
CARTRIDGE, output
seal
SCREW, cap, socket
head; M8 x 1.25; 30
mm
PLUG, oil drain
LABEL, warning
(EM0012, EM0022,
and EM0025)
LABEL, warning
(EM0014, EM0024,
and EM0026)
LABEL, warning
Ref
27
34▲
196548
38
16W645
43
———
4
1
▲ Replacement Danger and Warning labels, tags,
and cards are available at no cost.
3A2526H
16W360
1
1
1
4
Items marked — — — are not available separately.
23
Notes
Notes
24
3A2526H
Repair Kits, Related Manuals, and Accessories
Repair Kits, Related Manuals, and Accessories
Motor Part No.
Description
Kits
Kit Description
All motors in this
manual.
E-Flo DC Motors
24K341
Output Seal Cartridge (19); see
Parts, page 20.
24P816
Shaft Collector Kit; see manual 406998.
255143
Wall Bracket; see manual 312148.
16W645
ISO 220 Silicone-Free Synthetic Gear Oil;
1 quart (0.95 liter); order 2
16U705
Position Sensor; see
Position Sensor Replacement, page 33.
24U938
Encoder; see Encoder Replacement, page 30
108675
Wiring Post
16U113
Knob Kit (36); see Parts, page 20. Includes
replacement parts for one knob.
24U934
Electric 1HP Control Board; see
Control Board Replacement, page 27
24U936
Electric 2HP Control Board; see
Control Board Replacement, page 27
24P822
Control Module, for Advanced Motors; see
manual 3A2527.
16P911
CAN Cable, 3 ft (1 m)
16P912
CAN Cable, 25 ft (8 m)
24P979
Pneumatic Control for Back Pressure
Regulator; see manual 332142.
24R050
Pressure Transducer Kit
16U729
Start/Stop Switch. Allows pump to be shut
off while maintaining power to the control
module.
24U935
Electric 1HP Control Board see
Control Board Replacement, page 27
24U937
Electric 2HP Control Board
see Control Board Replacement, page 27
24U939
Powerboard
Models EM00X1,
EM00X3
Models EM0012,
EM0014,
EM0015,
EM0016,
EM0022,
EM0024,
EM0025, and
EM0026
3A2526H
E-Flo DC Basic Motors
E-Flo DC Advanced Motors
25
Repair Kits, Related Manuals, and Accessories
Motor Part No.
Description
Kits
Kit Description
All motors in this
manual.
Connection kits, to mount an
E-Flo DC Motor to an existing
pump lower. Kits include tie
rods, tie rod nuts, adapter,
and coupler.
288203
For 3000 and 4000 cc 4–Ball Lowers
288204
For Dura-Flo 1800 and 2400 Lowers
288205
For Dura-Flo 600, 750, 900, and 1200
Lowers
288206
For Dura-Flo 1000 Lowers
288207
For Xtreme 145, 180, 220, 250, and 290
Lowers
288209
For 750, 1000, 1500, and 2000 cc 4–Ball
Lowers with Enclosed or Open Wet Cup
288860
For Xtreme 85 and 115 Lowers
17K525
For 750, 1000, 1500, and 2000 cc Sealed
4–Ball Lowers
26
3A2526H
Control Board Replacement Kits 24U934, 24U936, 24U935, 24U937
Control Board Replacement
Kits 24U934, 24U936, 24U935, 24U937
Overview
2. Follow the Pressure Relief Procedure, page 13.
The main control board assembly manages the
operation of the E-Flo DC. It is permanently attached
to the electronics cover.
Tools Required
• 6 mm Hex Wrench
• Phillips Screwdriver (#1)
• Torque Wrench (15 ft-lb, 20 Nm)
Replacement Instructions
3. Decouple the pump lower from the motor per the
appropriate pump manual.
Disconnect Power Wires
1. See Remove the 4 bolts that hold on the wiring
box cover using a 6mm hex wrench. Place bolts
in a safe location.
2. Disconnect wires from post and ground screw
inside of cover.
3. Remove power cable and/or conduit from
electronics cover.
To avoid electric shock, turn off equipment power
and shut off power at main circuit breaker before
installing.
NOTICE
To avoid damage to the control board wear
grounding strap (Part No. 112190) and ground
appropriately.
Figure 16 Wiring Box Cover
Prepare Motor
1. Remove power from the motor. Follow
appropriate lock-out/tag-out procedures.
3A2526H
27
Control Board Replacement Kits 24U934, 24U936, 24U935, 24U937
Remove Electronics Cover
2. Secure loose wires into the clip inside the
housing.
For advanced models see
Install New Power Barrier Board, page 37.
Reset Dip Switch
NOTICE
To avoid equipment damage, carefully support the
cover when removing the last bolt. Hold the cover
horizontally and take care that the wires are not
pulled tight.
1. Remove the 12 bolts that hold on the electronics
cover using a 6mm hex wrench. Place bolts in a
safe location.
2. Support the cover after the bolts are removed to
prevent putting excess strain on the wires inside
the E-Flo DC.
Figure 17 Electronics Cover
Disconnect Control Board
To calibrate the unit a dip switch on the control board
must be toggled. There are two dip switches located
on the upper control board. Reset either dip switch
by toggling it to the opposite state. This signals
the control board that a replacement part has been
installed. The next time the unit is powered it will
proceed with an auto-calibration sequence.
NOTE: If you are performing more than one repair
procedure the dip switch only needs to be toggled
into the opposite state one time.
Figure 18 Dip Switch
Reinstall Electronics Cover
NOTE: The control board is inside the electronics
cover. To replace the control board the entire
electronics cover must be replaced.
1. To disconnect the control board unplug the
position sensor, encoder, temperature sensor,
and motor from the control board.
2. Remove wires from clip inside housing.
3. Remove any tie straps that may be present.
4. Set the electronics cover/control board aside.
Be sure that no wires are pinched between the
electronics cover and the motor housing. Pinched
wires may damage the control board and will impair
explosion-proof safety.
1. Reinstall electronics cover onto center housing.
2. Install the 12 bolts using a 6 mm hex wrench.
NOTE: Ensure the lock washers are still in place.
For advanced models see
Disconnect Power Barrier Board, page 36.
3. Torque the bolts to 15 ft-lb (20 Nm).
Install New Control Board
Reinstall Wiring Box Cover
1. Plug the position sensor, encoder, temperature
sensor, and motor into the new control board.
1. Connect wires from inside of wiring box. Refer to
torque instructions listed on placard inside of the
28
3A2526H
Control Board Replacement Kits 24U934, 24U936, 24U935, 24U937
wiring box. Connect power cable and/or conduit
to the electronics cover.
2. Reinstall cover onto wiring box.
3. Install the 4 bolts using a 6 mm hex wrench.
NOTE: Ensure the lock washers are still in place.
3. Midway through the auto-calibration process the
motor output shaft will pause as it moves to the
next step.
4. Ensure the auto-calibration process is complete
before continuing.
4. Torque the bolts to 15 ft-lb (20 Nm).
Reattach Pump Lower
Power Unit
1. Jog the output shaft on the pump lower and
reconnect the coupling nut.
1. Apply power to the unit to start the auto-calibration
process.
2. Torque to the proper level per the appropriate
pump manual.
2. The motor output shaft will run up and down over
the course of several minutes.
3A2526H
29
Encoder Replacement Kit 24U938
Encoder Replacement
Kit 24U938
Overview
Remove Electronics Cover
The encoder is used by the E-Flo DC for two
purposes. First, the encoder tells the control board
where the motor is in its mechanical rotation and
uses that information to properly control the motor
torque. Second, it controls stroke length by allowing
the control board to count the number of complete
motor rotations.
Tools Required
• 6 mm Hex Wrench
• .050 in Hex Wrench
• Phillips Screwdriver (#1)
• Torque Wrench (15 ft-lb, 20 Nm)
• Blue (medium) thread locking compound
NOTICE
To avoid equipment damage, carefully support the
cover when removing the last bolt. Hold the cover
horizontally and take care that the wires are not
pulled tight.
1. Remove the 12 bolts that hold on the electronics
cover using a 6mm hex wrench. Place bolts in a
safe location.
2. Support the cover after the bolts are removed to
prevent putting excess strain on the wires inside
the E-Flo DC.
Replacement Instructions
To avoid electric shock, turn off equipment power
and shut off power at main circuit breaker before
installing.
NOTICE
Figure 19 Electronics Cover
Remove Motor Cover
To avoid damage to the control board wear
grounding strap (Part No. 112190) and ground
appropriately.
Prepare Motor
1. Remove power from the motor. Follow
appropriate lock-out/tag-out procedures.
2. Follow the Pressure Relief Procedure, page 13.
1. Remove the 4 bolts that hold on the motor cover
using a 6mm hex wrench. Place bolts in a safe
location.
2. Set motor cover aside.
3. Decouple the pump lower from the motor per the
appropriate pump manual.
30
3A2526H
Encoder Replacement Kit 24U938
NOTE: The encoder connector is the smaller of
the two connections.
Figure 20 Motor Cover
Remove Encoder
1. Unplug the encoder cable from the control board
and the encoder and remove.
2. Loosen the 2 hub set screws (AA) using the
included .050” hex wrench.
3. Remove the 2 mounting screws (AC) with a
Phillips head screw driver.
4. Pull encoder off of rotor shaft.
NOTE: This procedure only requires the removal of
the 2 Phillips head mounting screws. All other bolts
should remain in place.
Figure 22 Encoder Cable
AE
Encoder connector cable
AF
Lower port of motor housing
2. Slide the new encoder onto the rotor shaft.
3. Apply a small amount of blue (medium) thread
locker to the 2 Phillips head mounting screws
(AC) and secure encoder mounting flange (AB)
to motor housing (AD).
4. Remove the 2 set screws (AA) from the encoder
hub using the included .050” hex wrench.
5. Apply a small amount of blue (medium) thread
locker to the set screws (AA) and screw back into
the encoder. Tighten hand tight.
6. Plug encoder cable into the encoder and the
control board.
Figure 21 Encoder
AA
Set screws
AB
Encoder mounting flange
AC
Phillips head mounting screws
AD
Motor housing
Install New Encoder
1. Place the encoder connector cable (AE) through
the motor housing lower port (AF).
3A2526H
Figure 23 Encoder
31
Encoder Replacement Kit 24U938
AA
Set screws
1. Reinstall electronics cover onto center housing.
AB
Encoder mounting flange
2. Install the 12 bolts using a 6 mm hex wrench.
AC
Phillips head mounting screws
AD
Motor housing
Reset Dip Switch
To calibrate the unit a dip switch on the control board
must be toggled. There are two dip switches located
on the upper control board. Reset either dip switch
by toggling it to the opposite state. This signals
the control board that a replacement part has been
installed. The next time the unit is powered it will
proceed with an auto-calibration sequence.
NOTE: If you are performing more than one repair
procedure the dip switch only needs to be toggled
into the opposite state one time.
NOTE: Ensure the lock washers are still in place.
3. Torque the bolts to 15 ft-lb (20 Nm).
Reinstall Motor Cover
1. Reinstall motor cover onto motor housing.
2. Install the 4 bolts that hold on the motor cover
using a 6mm hex wrench. Ensure the lock
washers are still in place.
3. Torque the bolts to 15 ft-lb (20 Nm).
Power Unit
1. Apply power to the unit to start the auto-calibration
process.
2. The motor output shaft will run up and down over
the course of several minutes.
Figure 24 Dip Switch
Reinstall Electronics Cover
3. Midway through the auto-calibration process the
motor output shaft will pause as it moves to the
next step.
4. Ensure the auto-calibration process is complete
before continuing.
Reattach Pump Lower
1. Jog the output shaft on the pump lower and
reconnect the coupling nut.
Be sure that no wires are pinched between the
electronics cover and the motor housing. Pinched
wires may damage the control board and will impair
explosion-proof safety.
32
2. Torque to the proper level per the appropriate
pump manual.
3A2526H
Position Sensor Replacement Kit 16U705
Position Sensor Replacement
Kit 16U705
Overview
Remove Electronics Cover
The position sensor is used by the E-Flo DC to
determine where the motor is in the stroke.
Tools Required
• 6 mm Hex Wrenches
• 13 mm Open-Ended Wrench
• 6 mm Open-Ended Wrench
• Phillips Screwdriver (#2)
• Torque Wrench (15 ft-lb, 20 Nm)
Replacement Instructions
NOTICE
To avoid equipment damage, carefully support the
cover when removing the last bolt. Hold the cover
horizontally and take care that the wires are not
pulled tight.
1. Remove the 12 bolts that hold on the electronics
cover using a 6mm hex wrench. Place bolts in a
safe location.
2. Support the cover after the bolts are removed to
prevent putting excess strain on the wires inside
the E-Flo DC.
To avoid electric shock, turn off equipment power
and shut off power at main circuit breaker before
installing.
NOTICE
To avoid damage to the control board wear
grounding strap (Part No. 112190) and ground
appropriately.
Prepare Motor
1. Remove power from the motor. Follow
appropriate lock-out/tag-out procedures.
2. Follow the Pressure Relief Procedure, page 13.
3. Decouple the pump lower from the motor per the
appropriate pump manual.
Figure 25 Electronics Cover
Remove Position Sensor
1. Unplug the position sensor from the control
board.
2. Unscrew the shield ground (AT) using a Phillips
screwdriver.
3. Loosen the position sensor jam nut (AS) using
a 13 mm wrench.
4. Unscrew the position sensor (AR) from the center
housing using a 6 mm open ended wrench.
NOTE: Allow wires to rotate with position sensor
to prevent twisting.
3A2526H
33
Position Sensor Replacement Kit 16U705
Figure 26 Dip Switch
Reinstall Electronics Cover
Install New Position Sensor
1. Carefully screw the replacement position sensor
into the center housing.
NOTE: Be careful not to damage the wires. The
wires will have to be rotated while the position
sensor is installed to prevent them from being
twisted.
2. Use the 6 mm wrench to complete the installation
of the position sensor. Be careful not to use
excessive torque. Stop once the position sensor
bottoms out in the bore.
NOTE: Do not over tighten the position sensor.
Damage to the position sensor may result.
3. Tighten the jam nut on the position sensor finger
tight.
NOTE: Do NOT use a wrench to tighten the jam
nut. Damage to the position sensor may result.
4. Install shield ground wire using a Phillips screw
driver.
Be sure that no wires are pinched between the
electronics cover and the motor housing. Pinched
wires may damage the control board and will impair
explosion-proof safety.
1. Reinstall electronics cover onto center housing.
2. Install the 12 bolts using a 6 mm hex wrench.
NOTE: Ensure the lock washers are still in place.
3. Torque the bolts to 15 ft-lb (20 Nm).
Power Unit
1. Apply power to the unit to start the auto-calibration
process.
2. The motor output shaft will run up and down over
the course of several minutes.
5. Plug the position sensor into the control board.
3. Midway through the auto-calibration process the
motor output shaft will pause as it moves to the
next step.
Reset Dip Switch
4. Ensure the auto-calibration process is complete
before continuing.
To calibrate the unit a dip switch on the control board
must be toggled. There are two dip switches located
on the upper control board. Reset either dip switch
by toggling it to the opposite state. This signals
the control board that a replacement part has been
installed. The next time the unit is powered it will
proceed with an auto-calibration sequence.
Reattach Pump Lower
1. Jog the output shaft on the pump lower and
reconnect the coupling nut.
2. Torque to the proper level per the appropriate
pump manual.
NOTE: If you are performing more than one repair
procedure the dip switch only needs to be toggled
into the opposite state one time.
34
3A2526H
Advanced Power Board Replacement Kit 24U939
Advanced Power Board Replacement
Kit 24U939
Tools Required
Disconnect Power Wires
• 6 mm Hex Wrenches
1. See Remove the 4 bolts that hold on the wiring
box cover using a 6mm hex wrench. Place bolts
in a safe location.
• 1/4” Nut Driver
• 5 mm Hex Wrench
• Phillips Screwdriver (#2)
• Torque Wrench (15 ft-lb, 20 Nm)
2. Disconnect wires from post and ground screw
inside of cover.
3. Remove power cable and/or conduit from
electronics cover.
Replacement Instructions
To avoid electric shock, turn off equipment power
and shut off power at main circuit breaker before
installing.
NOTICE
To avoid damage to the control board wear
grounding strap (Part No. 112190) and ground
appropriately.
Prepare Motor
1. Remove power from the motor. Follow
appropriate lock-out/tag-out procedures.
2. Follow the Pressure Relief Procedure, page 13.
3. Decouple the pump lower from the motor per the
appropriate pump manual.
3A2526H
Figure 27 Wiring Box Cover
Remove Control Module Bracket
If the control module is bracket mounted to the
electronics cover it must be removed prior to
removing the electronics cover.
1. Unsnap the control module from the bracket and
disconnect the cable from the electronics cover,
set control module aside.
2. Remove control module bracket from the
electronics cover, set bracket and hardware
aside.
35
Advanced Power Board Replacement Kit 24U939
Remove Electronics Cover
3. Remove any tie straps that are present.
4. Insert a small hex key into the lower left corner of
the partition and pull out.
NOTICE
To avoid equipment damage, carefully support the
cover when removing the last bolt. Hold the cover
horizontally and take care that the wires are not
pulled tight.
1. Remove the 12 bolts that hold on the electronics
cover using a 6mm hex wrench. Place bolts in a
safe location.
2. Support the cover after the bolts are removed to
prevent putting excess strain on the wires inside
the E-Flo DC.
5. Remove tie strap connecting the CAN bus wire
to the power barrier board (AN).
6. Use 1/4” nut driver to remove the 4 stand offs
(AM) from the corners of the power barrier board,
set aside.
7. Use a 5mm hex wrench to remove the 2 socket
headed cap screws (AP) from the power barrier
board, set aside.
Figure 28 Electronics Cover
8. Remove the power barrier board (AN) from the
unit.
Disconnect Power Barrier Board
NOTICE
The CAN bus on the power barrier board is
connected to the control board through a partition
inside the motor. To avoid equipment damage,
hold electronics cover in place until the CAN bus
cable is disconnected. Hold the cover horizontally
and take care that the wires are not pulled tight.
1. Disconnect barrier board power cable from the
control board.
2. Remove the 4 screws (AK) holding the partition
(AL) and power cable bracket (AJ) in place, set
aside.
36
3A2526H
Advanced Power Board Replacement Kit 24U939
Install New Power Barrier Board
Reinstall Electronics Cover
1. Insert the tie strap through the back of the power
barrier board.
2. Put new power barrier board in place and secure
using reserved screws. Tighten standoffs hand
tight. Torque socket head cap screws to 15 ft-lb
(20 Nm).
NOTE: Put all six screws in place before
tightening. The standoffs should be tightened
before the socket head cap screws.
3. Plug the CAN bus power into the power barrier
board.
Be sure that no wires are pinched between the
electronics cover and the motor housing. Pinched
wires may damage the control board and will impair
explosion-proof safety.
1. Reinstall electronics cover onto center housing.
2. Install the 12 bolts using a 6 mm hex wrench.
NOTE: Ensure the lock washers are still in place.
4. Tighten the tie strap around the wires to secure
them to the board.
3. Torque the bolts to 15 ft-lb (20 Nm).
5. Place partition back into place. Make certain the
notch for the wires is on the lower left side of the
partition and the wires are not being crushed.
Reinstall Wiring Box Cover
6. Insert bottom screws into the partition and
tighten.
7. Place power connect bracket into place and
secure with two screws.
8. Reconnect motor, temperature, reed switch,
encoder, and barrier board power wires to the
control board.
1. Connect wires from inside of wiring box. Refer to
torque instructions listed on placard inside of the
wiring box. Connect power cable and/or conduit
to the electronics cover.
2. Reinstall cover onto wiring box.
3. Install the 4 bolts using a 6 mm hex wrench.
NOTE: Ensure the lock washers are still in place.
4. Torque the bolts to 15 ft-lb (20 Nm).
3A2526H
37
Advanced Power Board Replacement Kit 24U939
Attach Control Module Bracket
1. Connect the control module cable to the
electronics cover.
2. Reattach the control module mounting bracket
onto the electronics cover.
3. Snap the control module into place on the
bracket.
Power Unit
1. Apply power to the unit to start the auto-calibration
process.
3. Midway through the auto-calibration process the
motor output shaft will pause as it moves to the
next step.
4. Ensure the auto-calibration process is complete
before continuing.
Reattach Pump Lower
1. Jog the output shaft on the pump lower and
reconnect the coupling nut.
2. Torque to the proper level per the appropriate
pump manual.
2. The motor output shaft will run up and down over
the course of several minutes.
38
3A2526H
Appendix A - System Control Drawing 24N637
Appendix A - System Control Drawing 24N637
NOTES FOR FIG. 16 AND 17:
1. The non-intrinsically safe terminals (power rail)
must not be connected to any device which uses
or generates more than Um = 250 Vrms or dc
unless it has been determined that the voltage
has been adequately isolated.
2. All motors must be bonded to the same high
integrity equipotential system.
3. Do not remove any cover until power has been
removed.
4. Installation should be in accordance with
ANSI/ISA RP12.06.01, installation of intrinsically
safe systems for hazardous (classified) locations,
and the National Electrical Code (ANSI/NFPA
70).
5. Installation in Canada should be in accordance
with the Canadian Electrical Code, CSA C22.1,
Part 1, Appendix F.
6. Reserved for future use.
7. Between one and eight motors may be connected
in series. The motors are connected with a CAN
cable (16P911 or 16P912). The side of the cable
with the red marking is connected to Port 1 of
one motor and the unmarked side of the cable is
connected to Port 2 of the next motor.
8. The first motor in the series (the one with no
CAN cable on Port 2) is installed with the power
jumper 24N910 connected to Port 2 and Port 3.
location or an associated IS apparatus in the
non-hazardous location. The side of the CAN
cable with the red marking is connected to Port
1 of the last motor and the unmarked side of
the cable is connected to the IS or associated
IS apparatus.
10. The output entity parameters given for Pins 1 and
4 in each of Ports 1 and 2 are the total current
and power available to both pins added together.
The current on Pin 1 and Pin 4 added together
will not exceed the listed Io, and the power output
from Pin 1 and Pin 4 added together will not
exceed the listed Po.
WARNING: Substitution of components
may impair intrinsic safety.
ADVERTISSEMENT: La substitution
de composants peut compromettre la
securite intrinseque.
Table 2 . Calculation Procedures
Zones
Uo ≤ Ui
Io ≤ Ii
Po ≤ Pi
Co ≥ Ci + Ccable
Lo ≥ Li + Lcable
Lo / Ro ≥ Li / Ri
9. The “last” motor in the series is connected
to either an IS apparatus in the hazardous
3A2526H
39
40
ASSOCIATED IS
APPARATUS
EXPLOSION PROOF
FLAME PROOF
AC POWER
NON-HAZARDOUS
LOCATION
IS
APPARATUS
9
COMMUNICATION
1
2
POWER
3
ADVANCED COMMUNICATION
MOTOR
EM0012/EM0022
COMMUNICATION
1
2
POWER
3
ADVANCED COMMUNICATION
MOTOR
EM0012/EM0022
HAZARDOUS (CLASSIFIED) LOCATION
7
COMMUNICATION
1
2
POWER
3
ADVANCED COMMUNICATION
MOTOR
EM0012/EM0022
COMMUNICATION
1
2
POWER
3
ADVANCED COMMUNICATION
MOTOR
EM0012/EM0022
COMMUNICATION
1
2
POWER
3
ADVANCED COMMUNICATION
MOTOR
EM0012/EM0022
COMMUNICATION
1
2
POWER
3
ADVANCED COMMUNICATION
MOTOR
EM0012/EM0022
COMMUNICATION
1
2
POWER
3
ADVANCED COMMUNICATION
MOTOR
EM0012/EM0022
POWER
3
8
24N910
IS POWER JUMPER
COMMUNICATION
1
2
ADVANCED COMMUNICATION
MOTOR
EM0012/EM0022
HAZARDOUS LOCATION
HIGH INTEGRITY GROUND
Appendix A - System Control Drawing 24N637
Figure 29 System Control Drawing 24N637, Sheet 1
3A2526H
Appendix A - System Control Drawing 24N637
Figure 30 System Control Drawing 24N637, Sheet 2
Table 3 . Port 3: Power Barrier Output Parameters
Power Barrier Output Parameters
Port 3: Male M12
5 Pin “A” Key
3A2526H
Pin
Units
Voc
Isc
Pt
La
Ca
Vmax
mA
mW
μH
μF
1
CAN Data Low
2
Power
17.9
646
2891
681
7.7
3
IS Ground
Return
—
—
—
—
—
4
CAN Data High
5
Shield
—
—
Not Connected
Not Connected
—
—
—
41
Appendix A - System Control Drawing 24N637
Table 4 . Ports 1 and 2: CAN Data/Power In and Out Entity Parameters
CAN Data High/Low Input Loads
Port 2: Male M12
5 Pin “B” Key
Port 1: Male M12
5 Pin “A” Key
Pin
Units
Vmax
Imax
Pi
Li
Ci
Vmax
mA
mW
μH
μF
1
CAN Data Low
2
VIN Power
17.9
725
2900
128
0
3
Signal Ground
—
—
—
—
—
4
CAN Data High
5
Shield
See Table 5 for Data based on the Number of Motors
See Table 5 for Data based on the Number of Motors
—
—
—
—
—
CAN Data High/Low Output Barriers
Port 2: Male M12
5 Pin “B” Key
Port 1: Male M12
5 Pin “A” Key
42
Pin
Units
Voc
Isc
Pt
La
Ca
Vmax
mA
mW
μH
μF
1
CAN Data Low
2
VIN Power
17.9
646
2891
681
7.7
3
Signal Ground
—
—
—
—
—
4
CAN Data High
5
Shield
See Table 5 for Data based on the Number of Motors
See Table 5 for Data based on the Number of Motors
—
—
—
—
—
3A2526H
Appendix A - System Control Drawing 24N637
Table 5 . Ports 1 and 2, Pins 1 and 4: CAN Data High and Low (applies to all CAN data pins shorted together
or to any individual pin; see Note 10 on page 26)
CAN Data High/Low Input Loads
Vmax
Imax
Pi
Li
Ci
Vmax
mA
mW
μH
μF
1
6
700
900
67
0.2
2
6
700
900
67
0.4
3
6
700
900
67
0.6
4
6
700
900
67
0.8
5
6
700
900
67
1.0
6
6
700
900
67
1.2
7
6
700
900
67
1.4
8
6
700
900
67
1.6
Number of
Motors
Units
CAN Data High/Low Output Barriers
Voc
Isc
Pt
La
Ca
Vmax
mA
mW
mH
μF
1
4.94
102
79
27.3
1000
2
4.94
179
158
8.88
1000
3
4.94
246
237
4.70
1000
4
4.94
305
316
3.06
1000
5
4.94
358
395
2.22
1000
6
4.94
407
474
1.72
1000
7
4.94
452
553
1.39
1000
8
4.94
494
632
1.17
1000
Number of
Motors
3A2526H
Units
43
Mounting Hole Pattern
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
44
3A2526H
Technical Data
Technical Data
E-Flo DC Motors
Metric
U.S.
Input voltage/Power:
Models EM0011,
EM0012, EM0013,
EM0014, EM0015,
and EM0016
100–130/ 200–240 VAC single phase, 50/60 Hz, 1.4 kVA
Models EM0021,
EM0022, EM0023,
EM0024, EM0025,
and EM0026
200–240 VAC, single phase, 50/60 Hz, 2.9 kVA
Maximum potential fluid
pressure:
Models EM0011,
EM0012, EM0013,
EM0014, EM0015,
and EM0016
218000/v (volume of lower in cc) = psi
1500/v (volume of lower in cc) = bar
Models EM0021,
EM0022, EM0023,
EM0024, EM0025,
and EM0026
436000/v (volume of lower in cc) = psi
3000/v (volume of lower in cc) = bar
Maximum continuous
cycle rate
20 cpm
Maximum force:
Models EM0011,
EM0012, EM0013,
EM0014, EM0015,
and EM0016
1400 lbf
6227 N
Models EM0021,
EM0022, EM0023,
EM0024, EM0025,
and EM0026
2800 lbf
12455 N
Power inlet port size
Ambient temperature
range
3/4–14 npt(f)
32–104°F
Sound data
Oil capacity
Oil specification
Weight
3A2526H
0–40°C
Less than 70 dB(A)
1.5 quarts
1.4 liters
Graco Part No. 16W645 ISO 220 silicone-free synthetic gear oil
99 lb
45 kg
45
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 3A2526
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS, MN 55440-1441 • USA
Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision H, February 2017

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