Graco 3A3165B, e-Xtreme™ Driver Owner's Manual

Instructions-Parts
e-Xtreme™ Driver
3A3165B
EN
Electric driver for application of finishing materials and protective coatings using e-Xtreme Sprayers.
For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual and the system
manual. Save these instructions.
See pages 3 for model and approvals
information.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Model Information............................................... 3
Driver Model ................................................ 3
Repair Kits and Accessories................................ 4
Related Manuals ................................................ 4
Warnings ........................................................... 5
Component Identification..................................... 8
Installation.......................................................... 9
Fill With Oil Before Using Equipment ............. 9
Power Supply Requirements......................... 9
Hazardous Area Cabling and Conduit
Requirements................................. 10
Grounding ................................................... 10
Connect the Power Supply ........................... 11
Operation ........................................................... 12
Startup ........................................................ 12
Shutdown .................................................... 12
Pressure Relief Procedure............................ 12
Driver Operation .......................................... 12
Maintenance ...................................................... 13
2
Preventive Maintenance Schedule ................ 13
Change the Oil............................................. 13
Check Oil Level ........................................... 13
Bearing Pre-Load......................................... 13
Error Code Troubleshooting ................................ 14
Standby Mode ............................................. 14
Error Codes Table........................................ 14
Repair................................................................ 16
Replace Output Seal Cartridge ..................... 16
Control Board Replacement ......................... 17
Encoder Replacement ................................. 19
Position Sensor Replacement ....................... 22
Parts.................................................................. 24
Driver Assembly: 24X901 ............................. 24
Mounting Hole Pattern ........................................ 25
Wiring Schematic................................................ 26
Technical Specifications...................................... 27
Graco Standard Warranty.................................... 28
3A3165B
Model Information
Model Information
Driver Model
Part
Series
Description
24X901
A
e-Xtreme Driver
0359
II 2 G
Ex db IIA T4 -5°C≤Ta≤50°C
FM15ATEX0060X
IECEx FMG 15.0035X
For Class I, Div. 1, Group D T4.
Class 1, Zone 1, AEx db IIA T4 -5°C≤Ta≤50°C
Ex d IIA T4 Gb -5°C≤Ta≤50°C
ti28402a
Figure 1 Driver Identification Label
List of Standards
• IEC 60079–0: 2011 (Ed 6)
• CSA C22.2 No. 0.4:2004 (R2013)
• IEC 60079–1: 2014 (Ed 7)
• CSA C22.2 No. 0.5:82 (R2012)
• EN 60079–0: 2012 +A11:2013 (Ed 6)
• CSA C22.2 No. 30:M86 (R2012)
• EN 60079–1: 2014 (Ed 7)
• CAN/CSA C22.2 60079–0:2011
• ANSI/ISA 60079–0: 2013 (Ed 6)
• ANSI/UL 60079–1: 2015 (Ed 7)
• FM 3600: 2011
• FM 3615: 2006
• FM 3810: 2005
3A3165B
• CAN/CSA C22.2 60079–1:2011
• CAN/CSA C22.2 No. 61010.1:2012
NOTE: Consult Graco Technical Assistance or your
Graco distributor if dimensional information on the
flameproof joint is necessary.
3
Repair Kits and Accessories
Repair Kits and Accessories
Driver Part
Description
Kits
Kit Description
24X901
e-Xtreme Driver
———
Output Seal Cartridge (19); see Parts, page 24.
255143
Wall Bracket; see manual 311619.
16W645
ISO 220 Silicone-Free Synthetic Gear Oil;
1 quart (0.95 liter); order 2
———
Position Sensor; see
Position Sensor Replacement, page 22.
24U938
Encoder; see Encoder Replacement, page 19.
108675
Wiring Post
16U113
Knob Kit (36); see Parts, page 24. Includes replacement
parts for one knob.
———
Software Update Kit
288207
For Xtreme 145 and 180cc Lower
Connection kits, to
mount an e-Xtreme
Driver to an existing
pump lower. Kits
include tie rods, tie
rod nuts, adapter, and
coupler.
Related Manuals
Part
Description
3A3164
e-Xtreme Ex35/Ex45 Sprayer
311619
Pump Mounting Kit Manual
4
3A3165B
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. 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.
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 driver as approved for hazardous
locations and are not repairable if damaged. Damaged parts must be replaced only with
genuine Graco parts with no substitutions.
3A3165B
5
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.
• Do not expose to rain. Store indoors.
• Wait five minutes before servicing after power is removed.
BURN HAZARD
Equipment surfaces and fluid that is 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.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
•
•
•
•
•
•
Do not spray without tip guard and trigger guard installed.
Engage trigger lock when not spraying.
Do not point gun at anyone or at any part of the body.
Do not put your hand over the spray tip.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
6
3A3165B
Warnings
WARNING
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 Safety Data Sheets (SDSs) 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. 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.
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 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.
3A3165B
7
Component Identification
Component Identification
Ref.
Description
A
Driver
C
Lift Ring
G
Oil Drain Plug
H
Driver Output Shaft
K
Oil Sight Glass
L
Status Indicator Light (LED)
N
Pressure Control Knob
P
Oil Fill Cap (vented)
S
Power Switch (Lock-out tag-out equipped)
Y
Electrical Junction Box
X
Conduit Entry
Z
Electrical Junction Box Cover
ZZ
Ground Screws
8
3A3165B
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.
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
1.0–1.2 quarts (0.9–1.1 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 the table below for power supply requirements.
The driver requires a dedicated circuit protected with
a circuit breaker. .
Model
Voltage
Phase
Hz
kVA
24X901
200–240
Vac
1
50/60
2.5
Select the minimum cord wire gauge based on length
according to the table below.
Length
Gauge
mm2
50 ft (15.2 m)
12 AWG
3.3
100 ft (30.4 m)
10 AWG
5.3
200 ft (61 m)
8 AWG
13.3
Figure 2 Sight Glass and Oil Fill Cap
NOTICE
Only use Graco GBL oil (Graco part number
16W645). Any other oil will not lubricate properly
and can cause damage to the drive train.
3A3165B
9
Installation
Hazardous Area Cabling and Conduit
Requirements
Grounding
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 is required within 18 in. (457
mm) of the driver for the US and Canada (see
Connect the Power Supply, page 11).
All cables must be rated at 70°C.
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.
The driver is grounded through the power cord.
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.
Pump Ground Wire – Two ground terminals are
provided if local code requires redundant grounding
connections.
Loosen the ground screw (ZZ) and attach a ground
wire (Graco part 244524 - not supplied). Tighten the
ground screw securely. Connect the other end of the
ground wire to a true earth ground.
10
3A3165B
Installation
Connect the Power Supply
3. Install the ground wire to the labeled ground
lug in the back of the junction box. See
Grounding, page 10.
Improper wiring may cause electric shock, fire
and explosion, 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. Install incoming power wires into the opposite
side of the disconnect labeled 2T1 and 4T2, and
torque to 7 in-lb (0.8 N•m).
5. Reinstall junction box cover (Z) and screws (J).
Torque screws to 15–20 ft-lb (21–27 N•m).
NOTE: One wire will be installed in both terminals
1L1 and 3L2.
1. Shut off the fused safety switch (B) and follow
the appropriate lock-out/tag-out procedures.
Typical fixed installation for wall mounted
systems shown below:
Be sure that no wires are pinched between the
electronics cover and the driver housing. Wires will
be damaged and create an electrical hazard and/or
fire and explosion hazard if pinched.
Disconnect Block Terminals
1
2
3
4
Tighten disconnect block terminals to 7 in-lb
(0.8 N•m). Do not over-tighten.
Tighten cover screws to 15 ft-lb (20.3 N•m).
A conduit seal (D) is required within 18 in.
(457 mm) of the driver for the US and Canada.
25 in-lb maximum (terminal bushings)
2. To install wiring, locate the electrical junction box
(Y). Remove four screws (J) and junction box
cover (Z). Wires will already be installed in the
front side of the disconnect in terminals labeled
1L1 and 3L2.
† Conduit not supplied.
‡ Power cord not supplied.
3A3165B
11
Operation
Operation
Startup
1. Unlock the fused safety switch (B) and turn it on.
See Connect the Power Supply, page 11
2. Turn the power switch (S) ON.
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
3. Check that the status indicator (L) is lit (steady
on).
4. See Driver Operation, page 12 for further
instructions.
This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized fluid, such as skin injection,
follow the Pressure Relief Procedure when you
stop spraying and before cleaning, checking, or
servicing the equipment.
1. Turn the power switch (S) OFF.
2. Shut off and lock out the fused safety switch (B).
See Connect the Power Supply, page 11.
3. Relieve all fluid pressure as explained in your
separate system manual.
Driver Operation
Shutdown
Pressure Control
Follow the Pressure Relief Procedure, page 12.
The driver will adjust the speed to maintain a constant
fluid pressure.
1. Pull the Pressure Control Knob (N) out to set.
2. Turn the Pressure Control Knob (N) fully
counterclockwise to 0.
3. Turn the knob clockwise to increase the pressure,
or counterclockwise to decrease the pressure.
Push the knob in to lock.
12
3A3165B
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 1.0–1.2 quarts (0.9–1.1
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 ISO 220
silicone-free synthetic gear oil (Graco Part No.
16W645).
1. Place a minimum 2 quart (1.9 liter) container
under the oil drain port. Remove the oil drain
plug (G). Allow all oil to drain from the driver.
2. Reinstall the oil drain plug (G). Torque to 25–30
ft-lb (34–40 N•m).
NOTICE
Do not over-torque. The drain plug can
become stripped and damaged.
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.–1.2
quarts (0.9–1.1 liters). Do not overfill.
Pre--Load
Bearing Pre
The bearing pre-loads (R) are factory set and are not
user adjustable. Do not adjust the bearing pre-loads.
4. Reinstall the fill cap.
3A3165B
13
Error Code Troubleshooting
Error Code Troubleshooting
Standby Mode
Error codes can take two forms:
• Alarm: Alerts you to the cause of the alarm and
shuts down the driver.
• Deviation: Alerts you to the problem, but the driver
may continue to run past the set limits until the
system absolute limits are reached.
NOTE: The blink code is displayed using the status
indicator (L) on the driver. The blink code given
below indicates the sequence. For example, blink
code 2 indicates two blinks, a pause, then two more
blinks, and then repeats.
When slow blinking is displayed, the driver has
entered Standby Mode. When the driver is on
and pressurized but the pump has not moved any
material, the driver will enter Standby Mode.
Standby Mode will be exited when:
• Material starts to dispense and causes the pump
to move, OR
• The pressure control knob (N) is adjusted, OR
• The power switch (S) is cycled OFF and ON
NOTE: To clear an error code, cycle power by turning
the power switch (S) to the OFF position for at least
30 seconds before turning back ON.
Error Codes Table
Blink Code
Error Type
Troubleshooting Steps
1
Alarm
Pump diving
The pump is diving rapidly.
• Verify that material is being properly fed to the pump.
• Verify that the check valve is installed and is properly working.
2
Alarm
Voltage Too Low
• Verify that line voltage is within the range specified in
Technical Specifications, page 27.
• Use the recommended cord in Power Supply Requirements, page 9 .
• Cycle power and check status indicator (L) to see if the error is still active.
3
Alarm
Voltage Too High
• Verify that line voltage is within the range specified in
Technical Specifications, page 27.
• Cycle power and check status indicator (L) to see if the error is still active.
4
Deviation
High Temperature
The temperature of the system is near the maximum operation temperature. The
performance has been reduced to prevent the driver from completely shutting
down.
• Check fan operation. Clean the fan and driver housing.
• Reduce pressure, duty cycle, or gun tip size.
• Move the unit to a cooler location.
14
3A3165B
Error Code Troubleshooting
Blink Code
Error Type
Troubleshooting Steps
5
Deviation
Low Temperature
• Warm equipment.
6
Alarm
Motor Temperature Fault
Motor is running too hot. Allow unit to cool.
• Check fan operation. Clean the fan and driver housing.
• Reduce pressure, duty cycle, or gun tip size.
• Move the unit to a cooler location.
7
Alarm
Board Temperature Fault
The control board is running too hot. Allow the unit to cool.
• Check fan operation. Clean the fan and driver housing.
• Reduce pressure, duty cycle, or gun tip size.
• Move the unit to a cooler location.
8
Alarm
Encoder Calibration Error
• Cycle power and check status indicator (L) to see if the error is still active.
• Calibrate the encoder (this code will blink if calibration is in progress).
• See Graco Contact Information ( Graco Standard Warranty, page 28).
9
Alarm
Encoder Error
• Cycle power and check the status indicator (L) to see if the error is still active.
• Verify that the internal connections are intact.
• See Graco Contact Information ( Graco Standard Warranty, page 28).
10
Alarm
Software Versions Do Not Match
• Obtain software update token and follow Software Update procedure (contact
your Graco distributor or Tech Service for more information).
11
Alarm
Circuit Board Communication Failure
• Cycle power and check status indicator (L) to see if the error is still active.
• See Graco Contact Information ( Graco Standard Warranty, page 28).
12
Alarm
Internal Circuit Board Hardware Failure
• Cycle power and check status indicator (L) to see if the error is still active.
• See Graco Contact Information ( Graco Standard Warranty, page 28).
13, 14
Alarm
Internal Software Error
• Cycle power and check status indicator (L) to see if the error is still active.
• See Graco Contact Information ( Graco Standard Warranty, page 28).
Slow Blink
3A3165B
Deviation
See Standby Mode, page 14.
15
Repair
Repair
Replace Output Seal Cartridge
1. Stop the pump at the bottom of its stroke. Shut
off and lock out power to the driver.
2. Follow the Pressure Relief Procedure, page 12.
3. Disconnect the lower from the driver, as
explained in your separate system manual.
To avoid electric shock, fire and explosion hazard,
and/or moving parts hazard, turn off equipment
power and shut off power at the main circuit
breaker before repairing. Wear appropriate
protective equipment when in work area. Wait five
minutes before servicing.
NOTE: Consult Graco Technical Assistance or your
Graco distributor for genuine replacement fasteners.
M8 x 30 socket-head cap screws of Class 12.9 steel
or better with a minimum yield strength of 1100 MPa
(160,000 psi) are acceptable alternatives.
4. Drain the oil from the driver. See
Change the Oil, page 13.
5. Reinstall the oil drain plug. Torque to 25–30 ft-lb
(34–40 N•m).
6. Unscrew the output cartridge (19) from the driver.
See Parts, page 24.
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 13.
9. Reconnect the lower to the driver.
10. Turn on power and resume operation.
16
3A3165B
Repair
Control Board Replacement
NOTICE
To avoid damage to the control board, wear
grounding strap (Graco Part No. 112190) and
ground appropriately.
Prepare Driver
1. Remove power from the driver. Follow
appropriate lock-out/tag-out procedures. Wait
five minutes before servicing. Wait five minutes
before servicing.
2. Follow the Pressure Relief Procedure, page 12.
Overview
3. Decouple the pump lower from the driver per the
system manual.
The main control board assembly manages the
operation of the driver. It is permanently attached
to the electronics cover.
Disconnect Power Wires
Tools Required
• 6 mm Hex Wrench
• Phillips Screwdriver (#1)
• Torque Wrench (15 ft-lb, 20 Nm)
1. Remove the screws (J) and junction box cover
(Z) from the electrical junction box (Y). Remove
screw (Ys) and sleeve housing.
2. Disconnect wires from terminal bushings L1 and
L2.
3. Remove the ground lug and disconnect the green
ground wire.
4. Disconnect wires from the opposite side of the
disconnect in terminals labeled 2T1 and 4T2.
3A3165B
17
Repair
Remove Electronics Cover
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 (CB) that hold on the
electronics cover using a 6 mm hex wrench.
Place bolts in a safe location.
1. Plug in all connectors. Ensure all connectors
(encoder, temperature sensor, and motor) are
securely attached to the control board. See
Wiring Schematic, page 26.
2. Secure loose motor wires into the clip inside the
housing (see Wiring Schematic, page 26).
3. Reinstall electronics cover onto center housing.
4. Install the 12 bolts using a 6 mm hex wrench.
NOTE: Ensure the lock washers are still in place.
5. Torque the bolts to 15 ft-lb (20 Nm).
2. Pull the cover straight off of the alignment pins
that hold the cover in place.
Reinstall Wiring Box Cover
3. Support the cover after it has been removed to
prevent putting excess strain on the wires inside.
See Connect the Power Supply, page 11.
Power Unit — Run Calibration Procedure
NOTE: The driver must be de-coupled from the lower
and must be able to cycle freely with no obstructions.
1. Cycle power to the driver by first turning the
power switch (S) OFF, and then ON again.
2. Wait for the status indicator LED (L) to turn on
solid or start blinking.
Disconnect Control Board
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 (see
Wiring Schematic, page 26).
2. Remove motor wires from clip inside housing
(see Wiring Schematic, page 26).
3. Set the electronics cover/control board aside.
Reinstall Electronics Cover onto Driver
3. Within 30 seconds, rapidly turn the pressure
control knob (N) back and forth from 0 to 10 at
least five times. If the status indicator LED (L)
was solid before, it will begin blinking an encoder
calibration error (code 8) during the calibration
process.
4. The driver output shaft (H) will run up and down
slowly over the course of several minutes.
5. Midway through the auto-calibration process the
driver output shaft (H) will pause as it moves to
the next step.
6. The driver output shaft (H) will move up and
down faster 5–6 times.
7. Ensure the auto-calibration process is complete
before continuing (wait for the LED to stop
blinking).
Reattach Pump Lower
Be sure that no wires are pinched between the
electronics cover and the driver housing. Wires will
be damaged and create an electrical hazard and/or
fire and explosion hazard if pinched.
18
See the system manual.
3A3165B
Repair
Encoder Replacement
NOTICE
To avoid damage to the encoder and control board,
wear grounding strap (Graco Part No. 112190)
and ground appropriately.
Overview
The encoder is used by the driver 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
Prepare Driver
1. Remove power from the driver. Follow
appropriate lock-out/tag-out procedures. Wait
five minutes before servicing. Wait five minutes
before servicing.
2. Follow the Pressure Relief Procedure, page 12.
3. Decouple the pump lower from the driver per the
system manual.
Remove Electronics Cover (When Also
Replacing the Encoder Cable)
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.
• 6 mm Hex Wrench
• .050 in Hex Wrench
• Phillips Screwdriver (#1)
• Torque Wrench (15 ft-lb, 20 Nm)
• Blue (medium) thread locking compound
1. Remove the 12 bolts (CB) that hold on the
electronics cover using a 6 mm hex wrench.
Place bolts in a safe location.
2. Pull the cover straight off of the alignment pins
that hold the cover in place.
3. Support the cover after it has been removed to
prevent putting excess strain on the wires inside.
3A3165B
19
Repair
Remove Motor Cover
Install New Encoder
1. Remove the 4 bolts that hold on the motor cover
using a 6 mm hex wrench. Place bolts in a safe
location.
1. If replacing the encoder cable (AE/AF) also,
place the encoder connector cable through the
motor housing.
2. Set motor cover aside.
NOTE: The encoder connector (AE) end is the
smaller of the two connectors.
Remove Encoder
1. If replacing the encoder cable also, unplug the
encoder cable (AE/AF)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 screwdriver.
4. Pull encoder (AB) 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.
Set screws
N•m).
5
AF
Control board connector (larger)
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 in. hex wrench.
5. Apply a small amount of blue (medium) thread
locker to the set screws (AA) and screw back into
the encoder. Tighten to 50 +/- 5 in-oz (0.35 N•m).
50 +/- 5 in-oz (0.35
AB
Encoder mounting flange
AC
Phillips head mounting screws
AD
Rotor Bearing Housing
20
Encoder connector (smaller)
6. Plug encoder cable into the encoder (AE). If
the encoder cable was also replaced, plug
the other end into the control board (AF). See
Wiring Schematic, page 26.
5
AA
AE
3A3165B
Repair
Reinstall Electronics Cover onto Driver (only
if removed to replace the encoder cable)
Reinstall Motor Cover
1. Reinstall motor cover onto driver housing.
Be sure that no wires are pinched between the
electronics cover and the driver housing. Wires will
be damaged and create an electrical hazard and/or
fire and explosion hazard if pinched.
1. Plug the position sensor, encoder, temperature
sensor, and motor into the control board (see
Wiring Schematic, page 26).
2. Secure loose motor wires into the clip inside the
housing (see Wiring Schematic, page 26).
2. Install the four bolts and washers that hold on the
motor cover using a 6 mm hex wrench. Ensure
the lock washers are still in place.
3. Reinstall electronics cover onto center housing.
3. Torque the bolts to 15 ft-lb (20 Nm).
4. Install the 12 bolts using a 6 mm hex wrench.
NOTE: Ensure the lock washers are still in place.
4. Follow the Power Unit — Run Calibration
Procedure, page 18.
5. Torque the bolts to 15 ft-lb (20 Nm).
Reattach Pump Lower
See the system manual.
3A3165B
21
Repair
Position Sensor Replacement
NOTICE
To avoid damage to the encoder and control board,
wear grounding strap (Graco Part No. 112190)
and ground appropriately.
Prepare Driver
1. Remove power from the driver. Follow
appropriate lock-out/tag-out procedures. Wait
five minutes before servicing. Wait five minutes
before servicing.
2. Follow the Pressure Relief Procedure, page 12.
Overview
3. Decouple the pump lower from the driver per the
system manual.
The position sensor is used to determine where the
driver output shaft (H) is in the stroke.
Remove Electronics Cover
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 N•m)
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 (CB) that hold on the
electronics cover using a 6 mm hex wrench.
Place bolts in a safe location.
2. Pull the cover straight off of the alignment pins
that hold the cover in place.
3. Support the cover after it has been removed to
prevent putting excess strain on the wires inside.
22
3A3165B
Repair
Remove Position Sensor
1. Unplug the position sensor (AR) from the control
board (see Wiring Schematic, page 26).
2. Loosen the position sensor jam nut (AS) using
a 13 mm wrench.
3. 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.
3. Tighten the jam nut on the position sensor finger
tight.
NOTICE
Do not use a wrench to tighten the jam nut.
Damage to the position sensor may result.
4. Plug the position sensor into the control board
(see Wiring Schematic, page 26).
Reinstall Electronics Cover onto Driver
Be sure that no wires are pinched between the
electronics cover and the driver housing. Wires will
be damaged and create an electrical hazard and/or
fire and explosion hazard if pinched.
1. Plug in all connectors. Ensure all connectors
(encoder, temperature sensor, and motor) are
securely attached to the control board. See
Wiring Schematic, page 26.
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.
2. Secure loose motor wires into the clip inside the
housing (see Wiring Schematic, page 26).
3. Reinstall electronics cover onto center housing.
4. Install the 12 bolts using a 6 mm hex wrench.
NOTE: Ensure the lock washers are still in place.
5. Torque the bolts to 15 ft-lb (20 Nm).
Reattach Pump Lower
See the system manual.
NOTICE
Do not over tighten the position sensor.
Damage to the position sensor may result.
3A3165B
23
Parts
Parts
Driver Assembly: 24X901
Ref.
Part
Description
Qty.
Ref.
Part
Description
1
———
HOUSING, driver
1
34▲
17K476
3
116343
SCREW, ground; M5 x 0.8
3
9
15F931
RING, lift
1
13
15H525
CAP, oil fill
1
14
24E315
SIGHT GLASS
1
4
19
———
CARTRIDGE, output seal
1
24
———
4
1
25
15H432
SCREW, cap, socket head; M8
x 1.25; 30 mm
PLUG, oil drain
27
———
COVER, electrical junction box
1
33▲
16T764
LABEL, warning
1
Qty.
36
16U113
38
16W645
43
———
LABEL, warning
(English/French/Spanish)
LABEL, warning, bag
(Dutch/German/Swedish,
Polish/Russian, Italian/Turkish)
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
44
16U979
LABEL, torque spec
1
45
———
HOUSING, junction box
1
46
———
SCREW, shcs
1
17J430
1
1
2
2
▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.
Items marked — — — are not available separately.
24
3A3165B
Mounting Hole Pattern
Mounting Hole Pattern
A
6.186 in. (157 mm)
B
6.186 in. (157 mm)
C
Four 3/8–16 Mounting Holes
D
Six 5/8–11 Tie Rod Holes:
• 8 in. (203 mm) x 120° bolt circle
OR
• 5.9 in. (150 mm) x 120° bolt circle
E
15.6 in. (395 mm)
F
15.75 in. (400 mm)
3A3165B
25
Wiring Schematic
Wiring Schematic
TOL 1
TOL 2
CC
DD
EE
FF
J6
J9
J7
J2
GG
AA
Install Motor Connector Under Clip
BB
Motor Temp
CC
Motor Power
DD
Token Cable
EE
Encoder
FF
Hall Sensor
GG (J7)
26
Reed Switch (not used)
3A3165B
Technical Specifications
Technical Specifications
e-Xtreme Driver Model 24X901
Metric
U.S.
Input voltage/power
200–240 VAC single phase, 50/60 Hz, 2.5 kVA
Minimum circuit breaker size
15 A
Maximum continuous cycle rate
Maximum force
44 cpm
18.7 kN
4,200 lbf
Power inlet port size
Ambient temperature range
3/4–14 npt(f)
25° – 120° F
Sound data
Oil capacity
Oil specification
Weight
Minimum recommended generator size
3A3165B
-5° – 50° 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
5 kW
27
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its
name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.
With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of
twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance
with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be
made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost
profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not
manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of
their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of
these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold
hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices
and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou
en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents.
To place an order, contact your Graco Distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free:
1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice. Original Instructions. This manual contains English. MM 3A3165
Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision B – February 2016

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