Graco 3A2526F User's Manual
Contents
1. 16 Bearing Pre Load 16 Error Code Troubleshooting 17 cp 19 Replace Output Seal Cartridge 19 ode hias cute ed be dod 20 Basic Motor Assembly 20 Advanced Motor Assembly 22 NOTES E 24 Repair Kits Related Manuals and iie esed eon ita s 25 Control Board Replacement Kits 24U934 240936 240935 240937 27 lo MISSUM 27 Tools Required 27 Replacement Instructions 27 Encoder Replacement Kit 24U938 29 OVGIVIGW Me 29 Tools Required 29 Replacement Instructions 29 Position Sensor Replacement Kit 16U705 32 cote ERR ec o LR Red 32 Tools Required 32 Replacement Instructions 32 Advanced Power Board Replacement Kit 240939 aa KANA Au dite un 34 Tools Required 34 Replacement Instructions 34 34 Disconnect Power 34 Remove Control Module Bracket2. 34 Remove Electronics Cover 34 Disconnect Power Barrier Board 35 Install New Power Barrier Board 35 Reinstall Electronics 35 Reinstall Wiring Box Cover 35 Attach Control Module Bracket 36 Power Unit eR Rien 36 Reattach Pump Lower 36 Appendix A System Control Drawing 2ANG3T y manaa eee ek 37 Mounting Hole Pattern 42 Technical Data 43 Graco Standard 44 3A2526F Models Models Basic Models Motor Part No Maximum Force Ibf N Series wow la la 1 C t US 0359 26 APPROVED For Class 1 Div 1 Group D T6 Ex db IIA T6 0 CsTas40 C Class 1 Zone 1 AEx db T6 0 C lt Tas40 C FM12ATEX0067X Ex d IIA T6 Gb 0 CsTas40 C IECEx FMG 12 0028X g lt E Flo DC Motor y PART NO SERIES NO MFG YR SERIAL NO GRACO 55440 U S A CE VOLTS kVA Hz O W2G Explosion proof For Class I Div 1 Group D T6 Ex db IIA T6 0 C lt Ta 40C Class 1 Zone 1 AEx db IIA T6 0 CsTas40 C FM12ATEX0067X Ex d IIA T6 Gb 0 CsTas40C h IECEx 12 0028X Use cables rated 70 C minimum Um 250 V Conduit seal requ
3. 2 The motor output shaft will run up and down over the course of several minutes 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 33 Advanced Power Board Replacement Kit 240939 Advanced Power Board Replacement Kit 240939 Tools Required 6 mm Hex Wrenches 1 4 Nut Driver 5 mm Hex Wrench Phillips Screwdriver 2 Torque Wrench 15 ft lb 20 Nm 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 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 34 ti237
4. 12 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 37 for installation requirements and entity parameters Follow all installation instructions in your system manual 3A2526F Operation Startup 1 Unlock the fused safety switch B and turn it on See Connect the Power Supply page 11 Press the start pushbutton C 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 ti20259a Figure 9 Power Indicator Shutdown Follow the Pressure Relief Procedure page 13 3A2526F Operation Pressure Relief Procedure 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 Shut off and lock out the fused saf
5. 2 vpower 725 zm 128 Ps E I ili CAN Data High Low Output Barriers Data CAN Data High Low Output Barriers Output Barriers voc amp P ta c vma m mw oF See Table 5 for Data based on the Number of Motors Tun power vs es e 77 TIIS See Table 5 for Data based on the Number of Motors Table 5 for Data based on See Table 5 for Data based on the Number of Motors Number of Motors WI I CAN Data Low CAN Data CAN Data High 3A2526F Appendix 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 3A2526F 41 Mounting Hole Pattern Mounting Hole Pattern ti20466a 6 186 in 157 mm 6 186 in 157 mm Four 3 8 16 Mounting Six 5 8 11 Tie Rod Holes Holes 8 in 203 mm x 120 bolt circle OR 59 150 mm x 120 bolt circle 42 3A2526F Technical Data Technical Data EF DG Moos us Mao Models EM0011 100 130 200 240 VAC single phase 50 60 Hz 1 4 kVA EM0012 EM0013 and EM0014 Models EM0021 200 240 VAC single phase 50 60 Hz 2 9 kVA EM0022 EM0023 EM0024 EM0025 and E
6. with the Canadian Electrical Code CSA C22 1 securite intrinseque Part 1 Appendix F 6 Reserved for future use Table 2 Calculation Procedures 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 l one motor and the unmarked side of the cable is P Pi connected to Port 2 of the next motor Co gt Ci Ccable Lo gt Li Lcable jumper 24N910 connected to Port 2 and Port 3 Lo Ro 2 Li Ri 8 The first motor in the series the one with no CAN cable on Port 2 is installed with the power 9 The last motor in the series is connected to either an IS apparatus in the hazardous 3A2526F 37 Appendix A System Control Drawing 24N637 w SI Snivuvddv 43dWNf YIMOA SI y OL6NYC 1 T 7 L 1 1 1 z l L z L 1 1 t W3MOd NOW INAWWOD u3M0d NOIIV3INOWWOD 4IMOd NOLIV3INOWWOD YIMOd NOLLYIINNWNOD NOLIYIINNWWO 4IMOd NOLIYJINNWWO u3MOd NOLWOINAWWOD aMmod NOLWOINNWWOD ZZ00W3 2100W3 Zz00W3 2100W3 TEOOW3 ZLOOWI TEOOW3 TLOOWI ZZ00W3 2100W3 TZOONI TLOOWF ZZOOW3 ZLOOW TZOOWI ZLOOWI YOLOW YOLOW YOLOW Y
7. 3A2526F ti23734a Figure 16 Wiring Box Cover 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 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 ti23735a Figure 17 Electronics Cover Disconnect Control Board NOTE The control board is inside the electronics cover To replace the control board the entire electronics cover must be replaced 27 Control Board Replacement Kits 240934 24U936 24U935 24U937 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 Setthe electronics cover control board aside For advanced models see Disconnect Power Barrier Board page 35 Install New Control Board 1 Plug the position sensor encoder temperature sensor and motor into the new control board 2 Secure loose wires into the clip inside the housing For advanced models see Install New Power Barrier Board page 35 Reset Dip Switch To calibrate the unit a dip switch on the control board must be toggled There are two di
8. pinched between the electronics cover and the motor housing Pinched wires may damage the control board and will impair explosion proof safety 3 Reinstall electronics cover onto center housing Install the 12 bolts using a 6 mm hex wrench NOTE Ensure the lock washers are still in place Torque the bolts to 15 ft Ib 20 Nm einstall Wiring Box Cover 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 Reinstall cover onto wiring box Install the 4 bolts using a 6 mm hex wrench NOTE Ensure the lock washers are still in place Torque the bolts to 15 ft Ib 20 Nm 35 Advanced Power Board Replacement Kit 240939 Attach Control Module Bracket 3 Midway through the auto calibration process the motor output shaft will pause as it moves to the 1 Connect the control module cable to the next step electronics cover 4 Ensure the auto calibration process is complete 2 Reattach the control module mounting bracket before continuing onto the electronics cover Reattach Pump Lower 3 Snap the control module into place on the bracket 1 Jog the output shaft on the pump lower and Power Unit reconnect the coupling nut 2 Torque to the proper level per the appropriate 1 Apply power to the unit to start the auto calibration pump manual process 2 The motor output shaft will run up and down over t
9. the new encoder onto the rotor shaft 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 3A2526F ti23741a Figure 23 Encoder Encoder mounting flange Phillips head mounting screws 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 ti23743a Figure 24 Dip Switch 3A2526F Encoder Replacement Kit 24U938 Reinstall Electronics Cover 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 housin
10. transducer is automatically cleared under this condition User must reassign For units without closed loop pressure control Transducer A or B is enabled but not detected The Mode Select knob is 3 between Pressure and Flow Set knob to the desired mode Basic and Advanced Basic and Advanced Basic and Advanced Basic and Advanced Basic and A blink code of 9 is not an error code but Advanced an indicator of which pump is active see NOTE above 18 3A2526F Replace Output Seal Cartridge Stop the pump at the bottom of its stroke Shut off and lock out power to the motor Follow the Pressure Relief Procedure page 13 Disconnect the lower from the motor as explained in your separate E Flo DC pump 9 Repair Drain the oil from the motor See Change the Oil page 16 Reinstall the oil drain plug Torque to 25 30 ft Ib 34 40 Nem Unscrew the output cartridge 19 from the motor See Parts page 20 Install the new output cartridge Torque to 70 80 ft lb 95 108 Nem Fill with oil See Change the Oil page 16 Reconnect the lower to the motor 10 Turn on power and resume operation 19 Parts Parts Basic Motor Assembly EM0011 Series A 1 Horsepower Motor EM0013 Series A 1 Horsepower Motor with Region Specific Approvals EM0021 Series A 2 Horsepower Motor EM0023 Series A 2 Horsepower Motor with Region Specific Approvals ti20138a 20 3A2
11. 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 ti19679a Figure 15 Sightglass and Oil 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 3A2526F Error Code Troubleshooting Error codes can take three forms Alarm alerts you to the alarm cause and shuts down the pump Deviation e 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 Applicable Motor Advanced Advanced Basic and Advanced Advanced Advanced Advanced Advanced Advanced None Basic and Advanced Basic and Advanced Advanced Advanced K4D Alarm Flow exceeds maximum target also indicates pump runaway condition exists None K3D Deviation Flow exceeds maximum target also indicates pump runaway condition exists 1 Deviation V11 Alarm Brown out voltage supplied to motor is too low 2 CAD Alarm Unit detects a loss of CAN communication This alarm is only logged No flashing a
12. with Integrated Runaway 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 1 Turn the Control Knob N fully counterclockwise to 0 2 Pull the Mode Select switch M out to set In the Runaway j 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 M N ti20172a Figure 12 Pressure Mode with Integrated Runaway Protection 3A2526F 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 43 1 Turn the Control Knob N fully counterclockwise to 0 Pull the Mode Select switch M out to set Turn the switch to Flow Push the switch in to lock 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
13. 34a 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 Remove Electronics Cover wall 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 3A2526F ti23735a Figure 28 Electronics Cover Disconnect Power Barrier Board 1 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 Disconnect barrier board power cable from the control board Remove the 4 screws AK holding the partition AL and power cable bracket AJ in place set aside Remove any tie straps that
14. 3615 2006 FM 3810 2005 CSA C22 2 No 0 4 2004 R2009 Specific Conditions of Use CSA C22 2 No 0 5 82 R2008 CSA C22 2 No 30 M86 R2007 CSA C22 2 No 157 92 R2006 CAN CSA E60079 0 2011 CAN CSA E60079 1 2011 CAN CSA C22 2 No 1010 1 2004 CAN CSA E60079 11 2011 ANSI ISA 60079 0 2009 ANSI ISA 60079 1 2009 ANSI ISA 60079 11 2011 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 cap screws of Class 12 9 steel or better with a minimum yield strength of 1100 MPa 160 000 psi are acceptable alternatives 3A2526F 5 Models Advanced Models with Region Specific Approvals C C us ao Ex d ia T6 0 lt lt 40 FM12ATEX0067X IECEx FMG 12 0028X GQ amp GRACO INC E Flo DC Motor Box PO Box i441 PART NO SERIES NO MFG YR SERIAL NO GRACO 55440 U S A C VOLTS Um 250 V kVA Hz o Css e I 2 1 G Ex db ia 6 0 lt 40 Use cables rated 70 C minimum FM12ATEX0067X IECEx FMG 12 0028X T No 16W334 Rev D 7 Figure 4 Advanced Motor with Region Specific Approvals Identification Label List of Standards EC 60079 0 2011 Ed 6 EN 60079 0 2012 IEC 60079 1 2007 w Corr 1 Ed 6 EN 60079 1 2007 EC 60079 11 2011 Ed 6 EN 60079 11 2012 Specific Conditions of Use 1 Consult the manufacturer if dimensi
15. 526F EM0011 Series A 1 Horsepower Motor EM0013 Series A 1 Horsepower Motor with Region Specific Approvals EM0021 Series A 2 Horsepower Motor EM0023 Series A 2 Horsepower Motor with Region Specific Approvals Ref 1 3 9 13 14 19 24 25 27 334 Replacement Danger and Warning labels tags Part 116343 15F931 15H525 24E315 24K341 15H432 16M130 Description HOUSING motor SCREW ground M5 x 0 8 RING lift CAP oil fill SIGHT GLASS CARTRIDGE output seal SCREW cap socket head M8 x 1 25 30 mm PLUG oil drain COVER electrical compartment LABEL warning EMOO11 and EM0021 and cards are available at no cost 3A2526F Qty 1 3 EX o Ref Part 16W360 344 196548 36 160113 38 16W645 4 Parts Description Qty LABEL warning 1 EM0013 and EM0023 LABEL warning KIT knob kit 2 includes replacement parts for one knob OIL gear synthetic ISO 220 silicone free 1 quart 0 95 liter not shown WASHER lock 4 spring no 8 N Items marked are not available separately 21 Parts Advanced Motor Assembly EM0012 Series A 1 Horsepower Motor EM0014 Series A 1 Horsepower Motor with Region Specific Approvals EM0022 Series A 2 Horsepower Motor EM0024 Series A 2 Horsepower Motor with Region Specific Approvals EM0025 Series A 2 Horsepower Motor EM0026 Series A 2 Horsepower Motor with Region S
16. BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns MIKA 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 MPa bar PSI 8 3A2526F MPa bar PSI 3A2526F Warnings 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 in
17. Instructions Parts GRACO E Flo DC Motor t S 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 ti20176a PROVEN QUALITY LEADING TECHNOLOGY Contents Model e 3 Basic Models 3 Basic Models with Region Specific Approvals 12 dade 4 Advanced Models 5 Advanced Models with Region Specific ADDBIOVaIS u xoti contient iet 6 Warnings sessirnir a aere ee NGA AGA 7 InstallatiOn 2 nde ertet neto 10 Fill With Oil Before Using Equipment 10 Power Supply Requirements 10 Connect the Power Supply 11 Gro nding oe pne en 12 Intrinsically Safe Installation Requirements for Advanced Motors 12 Operation iis e doe eode aded 13 iiu 13 ShULJOWN 4 erdt rai eh tee rn s 13 Pressure Relief Procedure 13 Advanced Motor Operation 13 Basic Motor 14 Maintenance spi uuu kia gu saad 16 Preventive Maintenance Schedule 16 Change the eene 16 Check Oil Level
18. M0026 Maximum potential fluid pressure Models EM0011 218000 v volume of lower in cc psi 1500 v volume of lower in cc bar EM0012 EM0013 and EM0014 Models EM0021 436000 v volume of lower in cc psi 3000 v volume of lower in cc bar EM0022 EM0023 EM0024 EM0025 and EM0026 Maximum continuous 20 cpm Maximum force force Models EM0011 aa Ibf 6227 N EM0012 EM0013 and EM0014 Models EM0021 2800 Ibf 12455 N EM0022 EM0023 EM0024 EM0025 and EM0026 Power inlet port size 3 4 14 npt f Ambient temperature 32 104 F 0 40 C range wn o o o o 3A2526F 43 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 neg
19. N clockwise to increase the cycle rate flow or counterclockwise to decrease the cycle rate flow 3A2526F Operation ti20173a Figure 13 Flow Mode 15 Maintenance Maintenance Preventive Maintenance Schedule 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 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 Nem 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 4 Reinstall the fill cap Figure 14 Oil Drain Plug 16 ti20883a Check Oil Level Check the oil level in the sight glass K The oil level should be near the halfway point of the sight glass when the
20. OLOW YOLOW YOLOW SOLON YOLON NOLIYINAWIWOD G3DNVAQV NOLIYJINNWWOD CIDNYAAY NOLLYINNWWOD Q32NVAGV NOLINDINDWWOD Q32NYAQV NOLLYDINAWWOD G3ONVAV NOLIYIINNWWOD Q32NVAQV NOLIYIINAWINO QDNVAOV NOLIN2INDWWOD aa NAGY ALIYDILNI HDIH NOLLW301 SNOGYYZYH SniveVddv 51931012055 NOIIV201 031155 12 SNOQYYZYH u3MOd 2v 300d 3AV13 30094 NOISOTdX3 NOLLV20T SNOQYYZYH NON Figure 29 System Control Drawing 24N637 Sheet 1 3A2526F 38 Appendix System Control Drawing 24N637 ti20263a Figure 30 System Control Drawing 24N637 Sheet 2 Table 3 Port 3 Power Barrier Output Parameters Power Barrier Output Parameters Port 3 Male M12 Voc ic Pt la Ca Cs TITI Return 3A2526F 39 Appendix System Control Drawing 24N637 Table 4 Ports 1 and 2 CAN Data Power In and Out Entity Parameters Port 2 Male M12 5 Pin B c ti20261a Port 1 Male M12 5 Pin A Key ti20260a Port 2 Male M12 5 Pin B Key Port 1 Male M12 5 Pin A Key ti20260a 40 CAN Data High Low Input Loads JI mA
21. are present Insert a small hex key into the lower left corner of the partition and pull out Remove tie strap connecting the CAN bus wire to the power barrier board AN Use 1 4 nut driver to remove the 4 stand offs AM from the corners of the power barrier board set aside Use a 5mm hex wrench to remove the 2 socket headed cap screws AP from the power barrier board set aside Remove the power barrier board AN from the unit nstall New Power Barrier Board barrier board using reserved screws Tighten standoffs hand 3A2526F Insert the tie strap through the back of the power Put new power barrier board in place and secure Advanced Power Board Replacement Kit 24U939 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 Plug the CAN bus power into the power barrier board Tighten the tie strap around the wires to secure them to the board 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 Insert bottom screws into the partition and tighten Place power connect bracket into place and secure with two screws Reconnect motor temperature reed switch encoder and barrier board power wires to the control board Reinstall Electronics Cover Be sure that no wires are
22. circuit breaker Table 1 Power Supply Specifications EM001x 100 130 1 50 60 1 4 200 240 Vac EM002x 200 240 Vac 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 Division 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 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 3A2526F 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 1 Ensure that the fused safety switch B is shut off and locked out ti20170a 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 moto
23. 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 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
24. ety switch B Relieve all fluid pressure as explained in your separate E Flo DC pump manual Advanced Motor Operation 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 E DO imn Figure 10 Control Module Accessory ti19866a 13 Operation Basic Motor Operation The basic motor has three operating modes Pressure Mode Pressure Mode with Integrated Runaway Protection Flow Mode NOTE Before changing from one mode to another turn the Control Knob N fully counterclockwise to 0 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 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 M N ti20171a Figure 11 Pressure Mode 14 Pressure Mode
25. g 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 Ib 20 Nm Reinstall Motor Cover wal 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 Ib 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 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 31 Position Sensor Replacement 16U705 Position Sensor Replacement Kit 16U705 Overview NOTICE u To avoid equipment damage carefully support the The position sensor is used by the E Flo DC to cover when removing the last bolt Hold the cover determine where the motor is in the stroke horizontally and take care that the wires are not Tools Required pulled tight 1 Remove the 12 bolts that hold on the electronics 6 mm Hex Wrenches cover using a 6mm hex wrench Place bolts in a 13 mm Open Ended Wrench safe location 2 Suppo
26. hall 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concer
27. harp 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 Installation Installation MPa bar PSI 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 ti18022a Figure 5 Sightglass and Oil Fill Cap 10 Power Supply Requirements 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
28. he course of several minutes 36 3A2526F Appendix System Control Drawing 24N637 Appendix System Control Drawing 24N637 NOTES FOR FIG 16 AND 17 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 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 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 3 Do not remove any cover until power has been The current on Pin 1 and Pin 4 added together removed will not exceed the listed lo and the power output from Pin 1 and Pin 4 added together will not exceed the listed Po 2 All motors must be bonded to the same high integrity equipotential system 4 Installation should be in accordance with ANSI ISA RP12 06 01 installation of intrinsically safe systems for hazardous classified locations WARNING Substitution of components and the National Electrical Code ANSI NFPA may impair intrinsic safety 70 ADVERTISSEMENT La substitution 5 Installation in Canada should be in accordance de composants peut compromettre la
29. ic 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 cap screws of Class 12 9 steel or better with a minimum yield strength of 1100 MPa 160 000 psi are acceptable alternatives 4 3A2526F Models Advanced Models CE lt I 0899 2 1 G APPROVED For Class Div 1 Group D T6 Ex db ia T6 0 lt lt 40 Class 1 Zone 1 AEx db ia IIA T6 0 lt lt 40 FM12ATEX0067X Ex db ia T6 0 lt lt 40 IECEx FMG 12 0028X E Flo DC Motor Box PART NO SERIES NO MFG YR SERIAL NO eraco 55440 U S A CE VOLTS kVA Hz O Css H2 1 G Explosion proof with intrinsically safe connections Ex db ia T6 0 406 For Class I Div 1 Group D T6 Install 24N637 FM12ATEX0067X Class 1 Zone 1 AEx db ia T6 0 C lt Ta 40 C n s IECEx FMG 12 0028X Ex db ia T6 0 C lt Tas40C Um 250 V Use cables rated 70 C minimum APPROVED Ga No 167556 Rev Conduit seal required within 18 inches for US and Canada Bul Figure 3 Advanced Motor Identification Label List of Standards IEC 60079 0 2011 Ed 6 IEC 60079 1 2007 w Corr 1 Ed 6 EC 60079 11 2011 Ed 6 EN 60079 0 2012 EN 60079 1 2007 EN 60079 11 2012 FM 3600 2011 FM 3610 2010 FM
30. ing 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 ti23735a Figure 19 Electronics Cover 29 Encoder Replacement 24U938 Remove Motor Cover wall Encoder mounting flange Phillips head mounting screws Motor housing 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 ti23739a 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 1i23741a AC Figure 21 Encoder 30 Install New Encoder 1 Place the encoder connector cable AE through the motor housing lower port AF NOTE The encoder connector is the smaller of the two connections IED AF ti23740a Figure 22 Encoder Cable Encoder connector cable Lower port of motor housing 2 Slide
31. ired within 18 inches for APPROVED T No 16T557 Rev G US and Canada d 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 cap screws of Class 12 9 steel or better with a minimum yield strength of 1100 MPa 160 000 psi are acceptable alternatives 3A2526F 3 Models Basic Models with Region Specific Approvals Ce Ex d T6 0 CsTas40 C FM12ATEX0067X IECEx FMG 12 0028X E Flo DC Motor 0 Box Minneapolis mn PART NO SERIES NO MFG YR SERIAL NO eraco 55440 U S A C VOLTS Um 250 V kVA Hz O Ce 2 Ex db IIA T6 0 406 Use cables rated 70 minimum FM12ATEX0067X IECEx FMG 12 0028X T No 16W333 Rev C E Figure 2 Basic Motor with Region Specific Approvals Identification Label List of Standards EC 60079 0 2011 Ed 6 EN 60079 0 2012 EC 60079 1 2007 w Corr 1 Ed 6 EN 60079 1 2007 Specif
32. jury 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 s
33. larm appears on the display but the blink code does occur None CAC Alarm Display detects a loss of CAN communication Flashing alarm appears on the display and the blink code occurs Error Code Troubleshooting 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 Blink Code Display Code Alarm or Description Deviation 2 1 3 7 i 3 Pressure exceeds maximum target CONTINUED ON THE NEXT PAGE 3A2526F 17 Error Code Troubleshooting Applicable Blink Code Display Code Alarm or Description Motor Deviation Advanced Alarm Display detects a loss of modbus communication when control access is set to modbus Basic and Alarm An internal control board hardware failure Advanced is detected Alarm Invalid lower size occurs if the unit is operated before setting up the lower size More than one pump is assigned to a transducer The assignment for that
34. less 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 3A2526F 7 Warnings 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
35. ligence 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 s
36. n es 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 F December 2014
37. on O All motors in this E Flo DC Motors 24K341 Output Seal Cartridge 19 see manual 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 32 24U938 Encoder see Encoder Replacement page 29 108675 Wiring Post Models EM00X1 E Flo DC Basic Motors 16U113 Knob Kit 36 see Parts page 20 Includes EM00X3 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 Models EM0012 E Flo DC Advanced Motors 24P822 Control Module for Advanced Motors see EM0014 manual 3A2527 EM0022 EM0024 16P911 CANCable3ft 1m EM0025 16 912 CAN Cable 25 ft 8 m EM0026 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 3A2526F 25 Repair Kits Related Manuals and Accessories All motors in this Connection kits to mount 288203 For 3000 and 4000 cc 4 Ball Lowers pump lower Kits incl
38. onal information on the flameproof joint is necessary 2 Consult the manufacturer 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 6 3A2526F 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 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 un
39. p 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 ti23743a Figure 18 Dip Switch 28 Reinstall Electronics Cover 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 Reinstall Wiring Box Cover 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 N Reinstall cover onto wiring box 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 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 3 Midway through the auto calibration process the motor outp
40. pecific Approvals ti20075a 22 3A2526F EM0012 Series A 1 Horsepower Motor EM0014 Series A 1 Horsepower Motor with Region Specific Approvals EM0022 Series A 2 Horsepower Motor EM0024 Series A 2 Horsepower Motor with Region Specific Approvals EM0025 Series A 2 Horsepower Motor EM0026 Series A 2 Horsepower Motor with Region Specific Approvals Ref 1 3 9 13 14 19 24 25 27 Replacement Danger and Warning labels tags Part 116343 15F931 15H525 24E315 24K341 15H432 Description HOUSING motor SCREW ground M5 x 0 8 RING lift CAP oil fill SIGHT GLASS CARTRIDGE output seal SCREW cap socket head M8 x 1 25 30 mm PLUG oil drain COVER electrical compartment and cards are available at no cost 3A2526F Qty 1 3 1 1 1 1 4 Ref Part 334 16M130 16W360 344 196548 38 16W645 4 Description LABEL warning EM0012 EM0022 and EM0025 LABEL warning EM0014 EM0024 and EM0026 LABEL warning OIL gear synthetic ISO 220 silicone free 1 quart 0 95 liter not shown WASHER lock spring no 8 Parts Qty N Items marked are not available separately 23 Notes Notes 24 3A2526F Repair Kits Related Manuals and Accessories Repair Kits Related Manuals and Accessories Motor Part No Description kits KitDescripti
41. r 3A2526F Installation 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 Ib 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 Nem A L C C AND LAN LAN al ILS Ee 3 4 14 npt f 118021 Figure 7 Connect Power Wires Notes for Fig 7 AN Tighten all terminal nuts to 25 in Ib 2 8 Nem maximum Do not over torque Tighten cover screws to 15 ft lb 20 3 Nem AN 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 Y ti18019a Figure 8 Ground Wire
42. rt the cover after the bolts are removed to prevent putting excess strain on the wires inside Phillips Screwdriver 2 the E Flo DC 6 mm Open Ended Wrench Torque Wrench 15 ft lb 20 Nm Replacement Instructions To avoid electric shock turn off equipment power and shut off power at main circuit breaker before installing ti23735a Figure 25 Electronics Cover Remove Position Sensor NOTICE 1 Unplug the position sensor from the control board To avoid damage to the control board wear E grounding strap Part No 112190 and ground 2 Unscrew the shield ground AT using a Phillips appropriately screwdriver 3 Loosen the position sensor jam nut AS using Prepare Motor a 13 mm wrench 1 Remove power from the motor Follow 4 Unscrew the position sensor AR from the center appropriate lock out tag out procedures housing using a 6 mm open ended wrench to prevent twisting 3 Decouple the pump lower from the motor per the appropriate pump manual Remove Electronics Cover Install New Position Sensor 1 Carefully screw the replacement position sensor A D 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 32 3A2526F 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 o
43. ude tie 288204 For Dura Flo 1800 and 2400 Lowers rods tie rod nuts adapter 288205 For Dura Flo 600 750 900 and 1200 and coupler 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 288860 For Xtreme 85 and 115 Lowers 26 3A2526F Control Board Replacement Kits 240934 24U936 24U935 24U937 Control Board Replacement Kits 24U934 24U936 24U935 24U937 Overview 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 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 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
44. ut 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 5 Plug the position sensor into the control board 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 ti23743a Figure 26 Dip Switch 3A2526F Position Sensor Replacement Kit 16U705 Reinstall Electronics Cover 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
45. ut 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 3A2526F Encoder Replacement Kit 24U938 Overview 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 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 3A2526F Encoder Replacement Kit 24U938 2 Follow the Pressure Relief Procedure page 13 3 Decouple the pump lower from the motor per the appropriate pump manual Remove Electronics Cover NOTICE To avoid equipment damage carefully support the cover when remov
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