Graco 3A2526F, E-Flo® DC Motor Owner's manual

Graco
Brand
Graco
Model
3A2526F, E-Flo® DC Motor
Category
Motor vehicle accessories & components
Type
Owner's manual

This manual is also suitable for

Instructions-Parts
E-Flo® E-Flo®
E-Flo®
DC DC
DC
Motor Motor
Motor
3A2526F
EN
Electric Electric
Electric
drive drive
drive
for for
for
low low
low
to to
to
medium medium
medium
volume volume
volume
paint paint
paint
circulation circulation
circulation
pumps. pumps.
pumps.
For For
For
professional professional
professional
use use
use
only. only.
only.
Important Important
Important
Safety Safety
Safety
Instructions Instructions
Instructions
Readallwarningsandinstructionsinthismanual.
Save Save
Save
these these
these
instructions. instructions.
instructions.
See page 3 for model part numbers and
approvals information.
PROVENQUALITY.LEADINGTECHNOLOGY.
Contents Contents
Contents
Models...............................................................3
BasicModels...............................................3
BasicModelswithRegion-Specic
Approvals.......................................4
AdvancedModels........................................5
AdvancedModelswithRegion-Specic
Approvals.......................................6
Warnings...........................................................7
Installation..........................................................10
FillWithOilBeforeUsingEquipment.............10
PowerSupplyRequirements.........................10
ConnectthePowerSupply...........................11
Grounding...................................................12
IntrinsicallySafeInstallationRequirements
forAdvancedMotors.......................12
Operation...........................................................13
Startup........................................................13
Shutdown....................................................13
PressureReliefProcedure............................13
AdvancedMotorOperation...........................13
BasicMotorOperation..................................14
Maintenance......................................................16
PreventiveMaintenanceSchedule................16
ChangetheOil.............................................16
CheckOilLevel...........................................16
BearingPre-Load.........................................16
ErrorCodeTroubleshooting................................17
Repair................................................................19
ReplaceOutputSealCartridge.....................19
Parts..................................................................20
BasicMotorAssembly..................................20
AdvancedMotorAssembly...........................22
Notes................................................................24
RepairKits,RelatedManuals,and
Accessories..........................................25
ControlBoardReplacementKits24U934,
24U936,24U935,24U937.....................27
Overview.....................................................27
ToolsRequired............................................27
ReplacementInstructions.............................27
EncoderReplacementKit24U938.......................29
Overview.....................................................29
ToolsRequired............................................29
ReplacementInstructions.............................29
PositionSensorReplacementKit16U705............32
Overview.....................................................32
ToolsRequired............................................32
ReplacementInstructions.............................32
AdvancedPowerBoardReplacementKit
24U939................................................34
ToolsRequired............................................34
ReplacementInstructions.............................34
PrepareMotor..............................................34
DisconnectPowerWires...............................34
RemoveControlModuleBracket...................34
RemoveElectronicsCover...........................34
DisconnectPowerBarrierBoard...................35
InstallNewPowerBarrierBoard...................35
ReinstallElectronicsCover...........................35
ReinstallWiringBoxCover...........................35
AttachControlModuleBracket......................36
PowerUnit...................................................36
ReattachPumpLower..................................36
AppendixA-SystemControlDrawing
24N637................................................37
MountingHolePattern........................................42
TechnicalData...................................................43
GracoStandardWarranty....................................44
2
3A2526F
Models
Models Models
Models
Basic Basic
Basic
Models Models
Models
Motor Motor
Motor
Part Part
Part
No. No.
No.
Series Series
Series
Horsepower Horsepower
Horsepower
Maximum Maximum
Maximum
Force, Force,
Force,
lbf lbf
lbf
(N) (N)
(N)
EM0011A1
1400(6227)
EM0021A2
2800(12455)
0359 0359
0359
II2G
ExdbIIAT60°C≤Ta≤40°C
FM12ATEX0067X
IECExFMG12.0028X
ForClassI,Div.1,GroupDT6.
Class1,Zone1,AExdbIIAT60°C≤Ta≤40°C
ExdIIAT6Gb0°C≤Ta≤40°C
Figure1BasicMotorIdenticationLabel
List List
List
of of
of
Standards Standards
Standards
•IEC60079–0:2011(Ed.6)
•IEC60079–1:2007w/Corr1(Ed6)
•EN60079–0:2012
•EN60079–1:2007
•ANSI/ISA60079–0:2009
•ANSI/ISA60079–1:2009
•FM3615:2006
•CSAC22.2No.0.4:2004(R2009)
•CSAC22.2No.0.5:82(R2008)
•CSAC22.2No.30:M86(R2007)
•CAN/CSA-E60079–0:2011
•CAN/CSA-E60079–1:2011
•CAN/CSAC22.2No.1010.1:2004
Specic Specic
Specic
Conditions Conditions
Conditions
of of
of
Use: Use:
Use:
1.Consultthemanufacturerifdimensional
informationontheameproofjointisnecessary.
2.Consultthemanufacturerforgenuine
replacementfasteners.M8x30socket-head
capscrewsofClass12.9steelorbetterwitha
minimumyieldstrengthof1100MPa(160,000
psi)areacceptablealternatives.
3A2526F 3
Models
Basic Basic
Basic
Models Models
Models
with with
with
Region Region
Region
- -
-
Specic Specic
Specic
Approvals Approvals
Approvals
Motor Motor
Motor
Part Part
Part
No. No.
No.
Series Series
Series
Horsepower Horsepower
Horsepower
Maximum Maximum
Maximum
Force, Force,
Force,
lbf lbf
lbf
(N) (N)
(N)
EM0013A1
1400(6227)
EM0023A2
2800(12455)
0359 0359
0359
II2G
ExdIIAT60°C≤Ta≤40°C
FM12ATEX0067X
IECExFMG12.0028X
Figure2BasicMotorwithRegion-SpecicApprovals
IdenticationLabel
List List
List
of of
of
Standards Standards
Standards
•IEC60079–0:2011(Ed.6)
•IEC60079–1:2007w/Corr1(Ed6)
•EN60079–0:2012
•EN60079–1:2007
Specic Specic
Specic
Conditions Conditions
Conditions
of of
of
Use: Use:
Use:
1.Consultthemanufacturerifdimensional
informationontheameproofjointisnecessary.
2.Consultthemanufacturerforgenuine
replacementfasteners.M8x30socket-head
capscrewsofClass12.9steelorbetterwitha
minimumyieldstrengthof1100MPa(160,000
psi)areacceptablealternatives.
4
3A2526F
Models
Advanced Advanced
Advanced
Models Models
Models
Motor Motor
Motor
Part Part
Part
No. No.
No.
Series Series
Series
Horsepower Horsepower
Horsepower
Maximum Maximum
Maximum
Force, Force,
Force,
lbf lbf
lbf
(N) (N)
(N)
EM0012A1
1400(6227)
EM0022A2
2800(12455)
EM0025A2
2800(12455)
0359 0359
0359
II2(1)G
Exdb[ia]IIAT60°C≤Ta≤40°C
FM12ATEX0067X
IECExFMG12.0028X
ForClassI,Div.1,GroupDT6.
Class1,Zone1,AExdb[ia]IIAT60°C≤Ta≤40°C
Exdb[ia]IIAT60°C≤Ta≤40°C
Figure3AdvancedMotorIdenticationLabel
List List
List
of of
of
Standards Standards
Standards
•IEC60079–0:2011(Ed.6)
•IEC60079–1:2007w/Corr1(Ed.6)
•IEC60079–11:2011(Ed.6)
•EN60079–0:2012
•EN60079–1:2007
•EN60079–11:2012
•FM3600:2011
•FM3610:2010
•FM3615:2006
•FM3810:2005
•CSAC22.2No.0.4:2004(R2009)
•CSAC22.2No.0.5:82(R2008)
•CSAC22.2No.30:M86(R2007)
•CSAC22.2No.157–92(R2006)
•CAN/CSA-E60079–0:2011
•CAN/CSA-E60079–1:2011
•CAN/CSAC22.2No.1010.1:2004
•CAN/CSA-E60079–11:2011
•ANSI/ISA60079–0:2009
•ANSI/ISA60079–1:2009
•ANSI/ISA60079–11:2011
Specic Specic
Specic
Conditions Conditions
Conditions
of of
of
Use: Use:
Use:
1.Consultthemanufacturerifdimensional
informationontheameproofjointisnecessary.
2.Consultthemanufacturerforgenuine
replacementfasteners.M8x30socket-head
capscrewsofClass12.9steelorbetterwitha
minimumyieldstrengthof1100MPa(160,000
psi)areacceptablealternatives.
3A2526F 5
Models
Advanced Advanced
Advanced
Models Models
Models
with with
with
Region Region
Region
- -
-
Specic Specic
Specic
Approvals Approvals
Approvals
Motor Motor
Motor
Part Part
Part
No. No.
No.
Series Series
Series
Horsepower Horsepower
Horsepower
Maximum Maximum
Maximum
Force, Force,
Force,
lbf lbf
lbf
(N) (N)
(N)
EM0014A1
1400(6227)
EM0024A2
2800(12455)
EM0026A2
2800(12455)
0359 0359
0359
II2(1)G
Exd[ia]IIAT60°C≤Ta≤40°C
FM12ATEX0067X
IECExFMG12.0028X
Figure4AdvancedMotorwithRegion-Specic
ApprovalsIdenticationLabel
List List
List
of of
of
Standards Standards
Standards
•IEC60079–0:2011(Ed.6)
•IEC60079–1:2007w/Corr1(Ed.6)
•IEC60079–11:2011(Ed.6)
•EN60079–0:2012
•EN60079–1:2007
•EN60079–11:2012
Specic Specic
Specic
Conditions Conditions
Conditions
of of
of
Use: Use:
Use:
1.Consultthemanufacturerifdimensional
informationontheameproofjointisnecessary.
2.Consultthemanufacturerforgenuine
replacementfasteners.M8x30socket-head
capscrewsofClass12.9steelorbetterwitha
minimumyieldstrengthof1100MPa(160,000
psi)areacceptablealternatives.
6 3A2526F
Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-specic
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-specichazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIRE
AND AND
AND
EXPLOSION EXPLOSION
EXPLOSION
HAZARD HAZARD
HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
work
area area
area
canigniteorexplode.Tohelp
preventreandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhenammable
fumesarepresent.
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Grounding
instructions.
•Useonlygroundedhoses.
•Holdgunrmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareantistaticorconductive.
•Stop Stop
Stop
operation operation
operation
immediately immediately
immediately
ifstaticsparkingoccursoryoufeelashock,Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworkingreextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
ammablevapors.Tohelppreventreandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
SPECIAL SPECIAL
SPECIAL
CONDITIONS CONDITIONS
CONDITIONS
FOR FOR
FOR
SAFE SAFE
SAFE
USE USE
USE
•Topreventtheriskofelectrostaticsparking,theequipment’snon-metallicpartsshouldbe
cleanedonlywithadampcloth.
•Thealuminumhousingmaysparkuponimpactorcontactwithmovingparts,whichmay
causereorexplosion.Takeprecautionstoavoidsuchimpactorcontact.
•Allameproofjointsarecriticaltotheintegrityofthemotorasapprovedforhazardous
locationsandarenotrepairableifdamaged.Damagedpartsmustbereplacedonlywith
genuineGracopartswithnosubstitutions.
3A2526F
7
Warnings
WARNING WARNING
WARNING
ELECTRIC ELECTRIC
ELECTRIC
SHOCK SHOCK
SHOCK
HAZARD HAZARD
HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingorinstallingequipment.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaqualiedelectricianandcomplywithalllocalcodes
andregulations.
INTRINSIC INTRINSIC
INTRINSIC
SAFETY SAFETY
SAFETY
Intrinsicallysafeequipmentthatisinstalledimproperlyorconnectedtonon-intrinsicallysafe
equipmentwillcreateahazardousconditionandcancausere,explosion,orelectricshock.
Followlocalregulationsandthefollowingsafetyrequirements.
•Besureyourinstallationcomplieswithnational,state,andlocalcodesfortheinstallationof
electricalapparatusinaClassI,GroupD,Division1HazardousLocation,includingallofthe
localsafetyrecodes,NFPA33,NEC500and516,andOSHA1910.107.
•Equipmentthatcomesincontactwiththeequipment’sintrinsicallysafeterminalsmust
meettheentityparameterrequirementsspeciedinControlDrawing24N637.See
IntrinsicallySafeInstallationRequirementsforAdvancedMotors,page12.Thisincludes
safetybarriers,DCvoltagemeters,ohmmeters,cables,andconnections.Removetheunit
fromthehazardousareawhentroubleshooting.
•Donotinstallanyequipmentapprovedonlyforanon-hazardouslocationinahazardous
area,asdenedinArticle500oftheNationalElectricalCode(USA)oryourlocalelectrical
code.SeetheIDlabelfortheintrinsicsafetyratingforyourequipment.
•Groundthemotor.Usea12gaugeminimumgroundwire,connectedtoatrueearthground.
SeeGrounding,page12.
•Donotoperatethemotorwithanycoverremoved.
•Donotsubstitutesystemcomponents,asthismayimpairintrinsicsafety.
BURN BURN
BURN
HAZARD HAZARD
HAZARD
Equipmentsurfacesanduidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhotuidorequipment.
MOVING MOVING
MOVING
PARTS PARTS
PARTS
HAZARD HAZARD
HAZARD
Movingpartscanpinch,cutoramputatengersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure
Pressure
Relief Relief
Relief
Procedure Procedure
Procedure
anddisconnectallpowersources.
8 3A2526F
Warnings
WARNING WARNING
WARNING
PRESSURIZED PRESSURIZED
PRESSURIZED
EQUIPMENT EQUIPMENT
EQUIPMENT
HAZARD HAZARD
HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
Pressure
Relief Relief
Relief
Procedure Procedure
Procedure
whenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenalluidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
TOXIC TOXIC
TOXIC
FLUID FLUID
FLUID
OR OR
OR
FUMES FUMES
FUMES
Toxicuidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadMSDSstoknowthespecichazardsoftheuidsyouareusing.
•Storehazardousuidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONAL
PROTECTIVE PROTECTIVE
PROTECTIVE
EQUIPMENT EQUIPMENT
EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisequipmentincludes
butisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbytheuidandsolvent
manufacturer.
EQUIPMENT EQUIPMENT
EQUIPMENT
MISUSE MISUSE
MISUSE
HAZARD HAZARD
HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorundertheinuenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
Technical
Data Data
Data
inallequipmentmanuals.
•Useuidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Data Data
Data
inallequipmentmanuals.Readuidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
Pressure
Relief Relief
Relief
Procedure Procedure
Procedure
whenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodicationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtrafcareas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
3A2526F 9
Installation
Installation Installation
Installation
Installationofthisequipmentinvolvespotentially
hazardousprocedures.Onlytrainedandqualied
personnelwhohavereadandwhounderstand
theinformationinthismanualshouldinstallthis
equipment.
NOTE: NOTE:
NOTE:
Toinstallanadvancedmotor,alsosee
IntrinsicallySafeInstallationRequirementsfor
AdvancedMotors,page12.
Fill Fill
Fill
With With
With
Oil Oil
Oil
Before Before
Before
Using Using
Using
Equipment Equipment
Equipment
Beforeusingtheequipment,openthellcap(P)and
addGracoPartNo.16W645ISO220silicone-free
syntheticgearoil.Checktheoillevelinthesightglass
(K).Filluntiltheoillevelisnearthehalfwaypointof
thesightglass.Theoilcapacityisapproximately1.5
quarts(1.4liters).Do Do
Do
not not
not
overll. overll.
overll.
NOTE: NOTE:
NOTE:
Two1quart(0.95liter)bottlesofoilare
suppliedwiththeequipment.
Figure5SightglassandOilFillCap
Power Power
Power
Supply Supply
Supply
Requirements Requirements
Requirements
Improperwiringmaycauseelectricshockorother
seriousinjuryifworkisnotperformedproperly.
Haveaqualiedelectricianperformanyelectrical
work.Besureyourinstallationcomplieswithall
National,StateandLocalsafetyandrecodes.
SeeTable1forpowersupplyrequirements.The
systemrequiresadedicatedcircuitprotectedwitha
circuitbreaker.
Table Table
Table
1 1
1
. .
.
Power Power
Power
Supply Supply
Supply
Specications Specications
Specications
Model* Model*
Model*
Voltage Voltage
Voltage
Phase Phase
Phase
Hz Hz
Hz
kVA kVA
kVA
EM001x100–130
/200–240
Vac
150/601.4
EM002x200–240
Vac
150/602.9
*ThelastdigitoftheModelNo.varies.Seethe
Models Models
Models
tablesonpages3–6.
Hazardous Hazardous
Hazardous
Area Area
Area
Cabling Cabling
Cabling
and and
and
Conduit Conduit
Conduit
Requirements Requirements
Requirements
Explosion Explosion
Explosion
Proof Proof
Proof
Allelectricalwiringinthehazardousareamustbe
encasedinClassI,DivisionI,GroupDapproved
explosion-proofconduit.FollowallNational,State,
andLocalelectriccodes.
Aconduitseal(D)isrequiredwithin18in.(457mm)
ofthemotorfortheUSandCanada.
Allcablesmustberatedat70°C.
Flame Flame
Flame
Proof Proof
Proof
(ATEX) (ATEX)
(ATEX)
Useappropriateconduit,connectors,andcable
glandsratedforATEXII2G.FollowallNational,
State,andLocalelectriccodes.
Allcableglandsandcablesmustberatedat70°C.
10 3A2526F
Installation
Connect Connect
Connect
the the
the
Power Power
Power
Supply Supply
Supply
Improperwiringmaycauseelectricshockorother
seriousinjuryifworkisnotperformedproperly.
Haveaqualiedelectricianperformanyelectrical
work.Besureyourinstallationcomplieswithall
National,StateandLocalsafetyandrecodes.
1.Ensurethatthefusedsafetyswitch(B)isshut
offandlockedout.
Figure6LockedOutFusedSafetySwitch
2.Installastart/stopcontrol(C)intheelectrical
supplyline(A),withineasyreachofthe
equipment.Thestart/stopcontrolmustbe
approvedforuseinhazardouslocations.
3.Opentheelectricalcompartment(S)onthe
motor.
4.Bringthepowerwiresintotheelectrical
compartmentthroughthe3/4–14npt(f)inletport.
Connectthewirestotheterminals,asshown.
Torquetheterminalnutsto25in-lb(2.8N•m)
maximum.Do Do
Do
not not
not
over-torque. over-torque.
over-torque.
5.Closetheelectricalcompartment.Torquethe
coverscrews(J)to15ft-lb(20.3N•m).
Figure7ConnectthePowerWires
Notes Notes
Notes
for for
for
Fig. Fig.
Fig.
7 7
7
Tightenallterminalnutsto25in-lb(2.8N•m)
maximum.Do Do
Do
not not
not
over over
over
- -
-
torque. torque.
torque.
Tightencoverscrewsto15ft-lb(20.3N•m).
Aconduitseal(D)isrequiredwithin18
in.(457mm)ofthemotorfortheUSand
Canada.
3A2526F
11
Installation
Grounding Grounding
Grounding
Thisequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
NOTE: NOTE:
NOTE:
ForadvancedmotorsEM0012and
EM0022,allmotorsmustbebondedtothe
samehighintegrityequipotentialsystem.See
IntrinsicallySafeInstallationRequirementsfor
AdvancedMotors,page12.
Loosenthegroundscrewandattachagroundwire
(Y).Tightenthegroundscrewsecurely.Connectthe
otherendofthegroundwiretoatrueearthground.
Figure8GroundWire
Intrinsically Intrinsically
Intrinsically
Safe Safe
Safe
Installation Installation
Installation
Requirements Requirements
Requirements
for for
for
Advanced Advanced
Advanced
Motors Motors
Motors
Donotsubstituteormodifysystemcomponents
asthismayimpairintrinsicsafety.Forinstallation,
maintenance,oroperationinstructions,read
instructionmanuals.Donotinstallequipment
approvedonlyfornon-hazardouslocationina
hazardouslocation.Seetheidenticationlabelfor
theintrinsicsafetyratingforyourmodel.
SeeAppendixA-SystemControlDrawing24N637,
page37,forinstallationrequirementsandentity
parameters.Followallinstallationinstructionsinyour
systemmanual.
12
3A2526F
Operation
Operation Operation
Operation
Startup Startup
Startup
1.Unlockthefusedsafetyswitch(B)andturniton.
SeeConnectthePowerSupply,page11
2.Pressthestartpushbutton(C).
3.Checkthatthepowerindicator(L)islit(steady
on).
4.SeeAdvancedMotorOperation,page13or
BasicMotorOperation,page14forfurther
instructions.
Figure9PowerIndicator
Shutdown Shutdown
Shutdown
FollowthePressureReliefProcedure,page13.
Pressure Pressure
Pressure
Relief Relief
Relief
Procedure Procedure
Procedure
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
fromsplashinguidandmovingparts,followthe
PressureReliefProcedurewhenyoustopspraying
andbeforecleaning,checking,orservicingthe
equipment.
1.Disengagethestart/stopcontrol(C).See
ConnectthePowerSupply,page11
2.Shutoffandlockoutthefusedsafetyswitch(B).
3.Relievealluidpressureasexplainedinyour
separateE-FloDCpumpmanual.
Advanced Advanced
Advanced
Motor Motor
Motor
Operation Operation
Operation
TheAdvancedE-FloDCmotorsrequireinstallationof
the24P822ControlModuleAccessoryKittoprovide
theinterfaceforuserstoenterselectionsandview
informationrelatedtosetupandoperation.Seethe
ControlModuleAccessoryKitmanualforinstallation
andoperationinformation.
NOTICE NOTICE
NOTICE
Topreventdamagetothesoftkeybuttons,donot
pressthebuttonswithsharpobjectssuchaspens,
plasticcards,orngernails.
Figure10ControlModuleAccessory
3A2526F 13
Operation
Basic Basic
Basic
Motor Motor
Motor
Operation Operation
Operation
Thebasicmotorhasthreeoperatingmodes:
•PressureMode
•PressureModewithIntegratedRunaway
Protection
•FlowMode
NOTE: NOTE:
NOTE:
Beforechangingfromonemodetoanother,
turntheControlKnob(N)fullycounterclockwiseto0.
Pressure Pressure
Pressure
Mode Mode
Mode
Wheninpressuremode,themotorwilladjustthe
speedtomaintainaconstantuidpressure.
1.TurntheControlKnob(N)fullycounterclockwise
to0.
2.PulltheModeSelectswitch(M)outtoset.Turn
theswitchtoPressure
.Pushtheswitchin
tolock.
3.PulltheControlKnob(N)outtoset.Turnthe
knobclockwisetoincreasethepressure,or
counterclockwisetodecreasethepressure.
Pushtheknobintolock.
Figure11PressureMode
Pressure Pressure
Pressure
Mode Mode
Mode
with with
with
Integrated Integrated
Integrated
Runaway Runaway
Runaway
Protection Protection
Protection
Inpressuremodewithintegratedrunawayprotection,
themotorwilladjustthespeedtomaintainaconstant
uidpressure,butwillshutdownifitexceedsa
user-setspeed.
1.TurntheControlKnob(N)fullycounterclockwise
to0.
2.PulltheModeSelectswitch(M)outtoset.In
theRunaway
range,turntheswitchtothe
desiredshutdownspeedincyclesperminute(5,
10,15,20,or25).Pushtheswitchintolock.
3.PulltheControlKnob(N)outtoset.Turnthe
knobclockwisetoincreasethepressure,or
counterclockwisetodecreasethepressure.
Pushtheknobintolock.
NOTE: NOTE:
NOTE:
Themotorwillshutdowniftheselected
speedisexceededfor5cycles.Toreset,turnthe
ControlKnob(N)fullycounterclockwiseto0,then
turntothedesiredpressure.
Figure12PressureModewithIntegratedRunaway
Protection
14
3A2526F
Operation
Flow Flow
Flow
Mode Mode
Mode
Wheninowmode,themotorwillmaintaina
constantspeedregardlessoftheuidpressure,up
tothepump’smaximumworkingpressure.See
TechnicalData,page43.
1.TurntheControlKnob(N)fullycounterclockwise
to0.
2.PulltheModeSelectswitch(M)outtoset.Turn
theswitchtoFlow
.Pushtheswitchinto
lock.
3.Theamountofowisdeterminedbythecycle
ratesetwiththeControlKnob(N).Theknob’s
scale(0–10)correspondstoacycleadjustment
rangeof0-30cyclesperminute.TurntheControl
Knob(N)clockwisetoincreasethecyclerate
(ow),orcounterclockwisetodecreasethecycle
rate(ow).
Figure13FlowMode
3A2526F 15
Maintenance
Maintenance Maintenance
Maintenance
Preventive Preventive
Preventive
Maintenance Maintenance
Maintenance
Schedule Schedule
Schedule
Theoperatingconditionsofyourparticularsystem
determinehowoftenmaintenanceisrequired.
Establishapreventivemaintenancescheduleby
recordingwhenandwhatkindofmaintenanceis
needed,andthendeterminearegularschedulefor
checkingyoursystem.
Change Change
Change
the the
the
Oil Oil
Oil
NOTE: NOTE:
NOTE:
Changetheoilafterabreak-inperiodof
200,000–300,000cycles.Afterthebreak-inperiod,
changetheoilonceayear.OrdertwoPartNo.
16W645ISO220silicone-freesyntheticgearoil.
1.Placeaminimum2quart(1.9liter)container
undertheoildrainport.Removetheoildrain
plug(25).Allowalloiltodrainfromthemotor.
2.Reinstalltheoildrainplug(25).Torqueto25–30
ft-lb(34–40N•m).
3.Openthellcap(P)andaddGracoPartNo.
16W645ISO220silicone-freesyntheticgear
oil.Checktheoillevelinthesightglass(K).Fill
untiltheoillevelisnearthehalfwaypointofthe
sightglass.Theoilcapacityisapproximately1.5
quarts(1.4liters).Do Do
Do
not not
not
overll. overll.
overll.
4.Reinstallthellcap.
Figure14OilDrainPlug
Check Check
Check
Oil Oil
Oil
Level Level
Level
Checktheoillevelinthesightglass(K).Theoil
levelshouldbenearthehalfwaypointofthesight
glasswhentheunitisnotrunning.Iflow,openthe
llcap(P)andaddGracoPartNo.16W645ISO220
silicone-freesyntheticgearoilasrequired.Theoil
capacityisapproximately1.5quarts(1.4liters).Do Do
Do
not not
not
overll. overll.
overll.
Figure15SightglassandOilFillCap
Bearing Bearing
Bearing
Pre Pre
Pre
- -
-
Load Load
Load
Thebearingpre-loads(R)arefactorysetandarenot
useradjustable.Donotadjustthebearingpre-loads.
16 3A2526F
ErrorCodeTroubleshooting
Error Error
Error
Code Code
Code
Troubleshooting Troubleshooting
Troubleshooting
Errorcodescantakethreeforms:
•Alarm:alertsyoutothealarmcauseandshuts
downthepump.
•Deviation:alertsyoutotheproblem,butpump
maycontinuetorunpastthesetlimitsuntilthe
system’sabsolutelimitsarereached.
•Advisory:informationonly.Pumpwillcontinueto
operate.
NOTE: NOTE:
NOTE:
OnAdvancedmotors,ow(Kcodes)and
pressure(Pcodes)canbedesignatedasalarms
ordeviations.SeeSetup Setup
Setup
Screen Screen
Screen
4 4
4
intheControl
ModuleManual.
NOTE: NOTE:
NOTE:
Intheerrorcodeslistedbelow,an“X”means
thecodeisassociatedwiththedisplayonly.
NOTE: NOTE:
NOTE:
Intheerrorcodeslistedbelow,a“?”inthe
codeisaplaceholderfortheunitnumberwherethe
eventoccurred.
NOTE: NOTE:
NOTE:
Theblinkcodeisdisplayedusingthepower
indicatoronthemotor.Theblinkcodegivenbelow
indicatesthesequence.Forexample,blinkcode1–2
indicates1blink,then2blinks;thesequencethen
repeats.
NOTE: NOTE:
NOTE:
Ablinkcodeof9isnotanerrorcode,but
anindicatorofwhichpumpisactive(
softkey
hasbeenpushed,seeRun Run
Run
Screen Screen
Screen
1 1
1
intheControl
ModuleManual).
Applicable Applicable
Applicable
Motor Motor
Motor
Blink Blink
Blink
Code Code
Code
Display Display
Display
Code Code
Code
Alarm Alarm
Alarm
or or
or
Deviation Deviation
Deviation
Description Description
Description
Advanced1–2
K1D?
AlarmFlowisbelowminimumlimit.
AdvancedNone
K2D?
DeviationFlowisbelowminimumlimit.
Basicand
Advanced
1
K4D?
AlarmFlowexceedsmaximumtarget;also
indicatespumprunawayconditionexists.
AdvancedNone
K3D?
DeviationFlowexceedsmaximumtarget;also
indicatespumprunawayconditionexists.
Advanced1–3
P1I?
AlarmPressureisbelowminimumlimit.
AdvancedNone
P2I?
DeviationPressureisbelowminimumlimit.
Advanced1–4
P4I?
AlarmPressureexceedsmaximumtarget.
AdvancedNone
P3I?
DeviationPressureexceedsmaximumtarget.
Basicand
Advanced
2
V1I?
AlarmBrownout;voltagesuppliedtomotoristoo
low.
Basicand
Advanced
3
V4I?
AlarmVoltagesuppliedtomotoristoohigh.
Advanced2–3
CAD?
Alarm
UnitdetectsalossofCANcommunication.
Thisalarmisonlylogged.Noashing
alarmappearsonthedisplay,buttheblink
codedoesoccur.
AdvancedNone
CAC?
Alarm
DisplaydetectsalossofCAN
communication.Flashingalarm
appearsonthedisplay,andtheblinkcode
occurs.
CONTINUED ON THE NEXT PAGE.
3A2526F
17
ErrorCodeTroubleshooting
Applicable Applicable
Applicable
Motor Motor
Motor
Blink Blink
Blink
Code Code
Code
Display Display
Display
Code Code
Code
Alarm Alarm
Alarm
or or
or
Deviation Deviation
Deviation
Description Description
Description
Advanced2–4
CAG?
Alarm
Displaydetectsalossofmodbus
communicationwhencontrolaccessisset
tomodbus.
Basicand
Advanced
4
WXD?
Alarm
Aninternalcontrolboardhardwarefailure
isdetected.
Advanced1–5
WSD?
Alarm
Invalidlowersize;occursiftheunitis
operatedbeforesettingupthelowersize.
Basicand
Advanced
5
T3D?
Deviation
Overtemperature.
AdvancedNoneP5DXDeviationMorethanonepumpisassignedtoa
transducer.Theassignmentforthat
transducerisautomaticallyclearedunder
thiscondition.Usermustreassign.
AdvancedNone
P6CAor
P6CB
DeviationForunitswithoutclosedlooppressure
control:Transducer(AorB)isenabled
butnotdetected.
Advanced1–6
P6D?
AlarmForunitswithclosedlooppressurecontrol:
Transducerisenabledbutnotdetected.
AdvancedNone
MND?
AdvisoryMaintenancecounterisenabledand
countdownreachedzero(0).
Basic6NoneAlarm
TheModeSelectknobissetbetween
PressureandFlow.Setknob
tothedesiredmode.
Basicand
Advanced
2–6
V1M?
Alarm
ACpowerislost.
Basicand
Advanced
3–5
T2D?
AlarmInternalthermistordisconnected.
Basicand
Advanced
3–4
WNC?
Alarm
Softwareversionsdonotmatch.
Basicand
Advanced
3–6
CCN?
Alarm
Circuitboardcommunicationfailure.
Basicand
Advanced
4–5
WMC?
Alarm
Internalsoftwareerror.
Basicand
Advanced
9NoneNone
Ablinkcodeof9isnotanerrorcode,but
anindicatorofwhichpumpisactive(see
NOTE NOTE
NOTE
above).
18 3A2526F
Repair
Repair Repair
Repair
Replace Replace
Replace
Output Output
Output
Seal Seal
Seal
Cartridge Cartridge
Cartridge
1.Stopthepumpatthebottomofitsstroke.Shut
offandlockoutpowertothemotor.
2.FollowthePressureReliefProcedure,page13.
3.Disconnectthelowerfromthemotor,as
explainedinyourseparateE-FloDCpump
manual.
4.Draintheoilfromthemotor.See
ChangetheOil,page16.
5.Reinstalltheoildrainplug.Torqueto25–30ft-lb
(34–40N•m).
6.Unscrewtheoutputcartridge(19)fromthemotor.
SeeParts,page20.
7.Installthenewoutputcartridge.Torqueto70–80
ft-lb(95–108N•m).
8.Fillwithoil.SeeChangetheOil,page16.
9.Reconnectthelowertothemotor.
10.Turnonpowerandresumeoperation.
3A2526F 19
Parts
Parts Parts
Parts
Basic Basic
Basic
Motor Motor
Motor
Assembly Assembly
Assembly
EM0011, EM0011,
EM0011,
Series Series
Series
A, A,
A,
1 1
1
Horsepower Horsepower
Horsepower
Motor Motor
Motor
EM0013, EM0013,
EM0013,
Series Series
Series
A, A,
A,
1 1
1
Horsepower Horsepower
Horsepower
Motor, Motor,
Motor,
with with
with
Region-Specic Region-Specic
Region-Specic
Approvals Approvals
Approvals
EM0021, EM0021,
EM0021,
Series Series
Series
A, A,
A,
2 2
2
Horsepower Horsepower
Horsepower
Motor Motor
Motor
EM0023, EM0023,
EM0023,
Series Series
Series
A, A,
A,
2 2
2
Horsepower Horsepower
Horsepower
Motor, Motor,
Motor,
with with
with
Region-Specic Region-Specic
Region-Specic
Approvals Approvals
Approvals
20 3A2526F
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Graco 3A2526F, E-Flo® DC Motor Owner's manual

Graco
Brand
Graco
Model
3A2526F, E-Flo® DC Motor
Category
Motor vehicle accessories & components
Type
Owner's manual
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