Graco e-Xtreme Driver User manual

Instructions
e e
e- - -Xtreme® Xtreme® Xtreme®Driver Driver Driver3A5124B
EN
Electric Electric
Electricdriver driver driverfor for forapplication application applicationof of of󰘰nishing 󰘰nishing 󰘰nishingmaterials materials materialsand and andprotective protective protectivecoatings coatings coatingsusing using usinge e e- - -Xtreme Xtreme XtremeSprayers. Sprayers. Sprayers.
For For
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandthesystem
manual.Saveallinstructions.
See pages 3 for model and approvalsinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
ModelInformation...............................................2
DriverModel................................................2
RelatedManuals................................................2
Warnings...........................................................3
ComponentIdenti󰘰cation.....................................6
Setup.................................................................7
InstallVentedOilCapBeforeUsing
Equipment......................................7
Grounding..........................................................7
Operation...........................................................8
Startup........................................................8
Shutdown....................................................8
PressureReliefProcedure............................8
DriverOperation.................................................9
PressureControl..........................................9
Maintenance......................................................9
PreventiveMaintenanceSchedule................9
ChangetheOil.............................................9
CheckOilLevel...........................................9
BearingPre-Load.........................................9
ErrorCodeTroubleshooting................................10
StandbyMode.............................................10
ErrorCodesTable........................................10
Repair................................................................12
ReplaceOutputSealCartridge.....................12
SoftwareTokenUpdate................................13
ControlBoardReplacement(25C187)
.....................................................14
EncoderReplacement(25C169)...................16
PositionSensorReplacement
(24W120).......................................19
Notes................................................................21
Parts..................................................................22
DriverAssembly:24X901.............................22
RepairKitsandAccessories................................24
MountingHolePattern........................................25
WiringSchematic................................................26
TechnicalSpeci󰘰cations......................................27
GracoExtendedWarranty...................................28
Model Model
ModelInformation Information Information
Driver Driver
DriverModel Model Model
Part Part
PartSeries Series
SeriesDescription Description
Description
24X901Ae-XtremeDriver
2575 2575
2575II2G
ExdbIIAT4-5°C≤Ta≤50°C
FM15ATEX0060X
IECExFMG15.0035X
ForClassI,Div.1,GroupDT4.
Class1,Zone1,AExdbIIAT4-5°C≤Ta≤50°C
ExdIIAT4Gb-5°C≤Ta≤50°C
Related Related
RelatedManuals Manuals Manuals
Manualsareavailableatwww.graco.com.
ComponentmanualsinEnglish:
Manuals Manuals
Manuals
in in
inEnglish English English
Description Description
Description
3A3165e-XtremeDriverInstallation
3A3164e-XtremeEx35/Ex45Sprayer
311619PumpMountingKitManual
2
3A5124B

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
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Neversprayor󰘱ushsolventathighpressure.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareanti-staticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
SPECIAL SPECIAL
SPECIALCONDITIONS CONDITIONS CONDITIONSFOR FOR FORSAFE SAFE SAFEUSE USE USE
•Topreventtheriskofelectrostaticsparking,theequipment’snon-metallicpartsshouldbe
cleanedonlywithadampcloth.
•Thealuminumhousingmaysparkuponimpactorcontactwithmovingparts,whichmay
cause󰘰reorexplosion.Takeprecautionstoavoidsuchimpactorcontact.
•All󰘱ameproofjointsarecriticaltotheintegrityofthedriverasapprovedforhazardous
locationsandarenotrepairableifdamaged.Damagedpartsmustbereplacedonlywith
genuineGracopartswithnosubstitutions.
3A5124B 3

Warnings
WARNING WARNING
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingorinstallingequipment.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
•Donotexposetorain.Storeindoors.
•Wait󰘰veminutesbeforeservicingafterpowerisremoved.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthatisheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromdispensingdevice,hoseleaks,orrupturedcomponentswillpierce
skin.Thismaylooklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Get
immediate immediate
immediatesurgical surgical surgicaltreatment. treatment. treatment.
•Donotspraywithouttipguardandtriggerguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopsprayingandbeforecleaning,checking,
orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
4
3A5124B

Warnings
WARNING WARNING
WARNING
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheets(SDSs)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Protectiveequipment
includesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestSafetyDataSheets(SDSs)from
distributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
3A5124B 5

ComponentIdentication
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
Ref. Ref.
Ref.Description Description
Description
ADriver
B*FusedSafetySwitch(notshown)
CLiftRing
GOilDrainPlug
HDriverOutputShaft
KOilSightGlass
LStatusIndicatorLight(LED)
NPressureControlKnob
P**OilFillCap(vented)
SPowerSwitch(Lock-outtag-outequipped)
YElectricalJunctionBox
XConduitEntry
ZElectricalJunctionBoxCover
ZZGroundScrews
*Thedriverrequiresadedicatedcircuitprotectedbyacircuitbreakerorfusedsafetyswitch.SeeDriver
Installationmanualfordetails.
**Thedrivershipspre-󰘰lledwithoilfromthefactory.Thetemporaryunventedcapisforshippingpurposes
onlyandmustbereplacedwiththesuppliedventedcapbeforeuse.
6 3A5124B

Setup
Setup Setup
Setup
SeeDriverInstallationmanualforpower
supplyrequirementsforwiringforhazardous
locations/explosiveatmospheres.
Installationofthisequipmentinvolvespotentially
hazardousprocedures.Onlytrainedandquali󰘰ed
personnelwhohavereadandwhounderstand
theinformationinthismanualshouldinstallthis
equipment.
Install Install
InstallVented Vented VentedOil Oil OilCap Cap CapBefore Before BeforeUsing Using Using
Equipment Equipment
Equipment
Thetemporaryunventedcap(PX)preventsoil
leaksduringshipment.Thistemporarycapmustbe
replacedwiththesuppliedventedoilcap(P)before
use.
PX
P
ti31010a
Grounding Grounding
Grounding
Thisequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
Driver: Driver:
Driver:Thedriverisgroundedthroughthepower
cord.
Driver Driver
Driver(optional (optional (optionalsecondary): secondary): secondary):Twogroundterminals
areprovidediflocalcoderequiresredundant
groundingconnections.
Loosenthegroundscrew(ZZ)andattachaground
wire(Gracopart244524-notsupplied).Tightenthe
groundscrewsecurely.Connecttheotherendofthe
groundwiretoatrueearthground.
3A5124B
7

Operation
Operation Operation
Operation
Startup Startup
Startup
1.Unlockthefusedsafetyswitch(B)andturniton.
2.Turnthepowerswitch(S)ON.
3.Checkthatthestatusindicator(L)islit(steady
on).
Shutdown Shutdown
Shutdown
FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure.
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
frommovingpartsorpressurized󰘱uid,suchas
skininjection,followthePressureReliefProcedure
whenyoustopsprayingandbeforecleaning,
checking,orservicingtheequipment.
1.Turnthepowerswitch(S)OFF.
2.Shutoffandlockoutthefusedsafetyswitch(B).
3.Relieveall󰘱uidpressureasexplainedinyour
separatesystemmanual.
8 3A5124B

DriverOperation
Driver Driver
DriverOperation Operation Operation
Pressure Pressure
PressureControl Control Control
Thedriverwilladjustthespeedtomaintainaconstant
󰘱uidpressure.
1.PullthePressureControlKnob(N)outtoset.
2.TurnthePressureControlKnob(N)fully
counterclockwiseto0.
3.Turntheknobclockwisetoincreasethepressure,
orcounterclockwisetodecreasethepressure.
Pushtheknobintolock.
Maintenance Maintenance
Maintenance
Preventive Preventive
PreventiveMaintenance Maintenance MaintenanceSchedule Schedule Schedule
Theoperatingconditionsofyourparticularsystem
determinehowoftenmaintenanceisrequired.
Establishapreventivemaintenancescheduleby
recordingwhenandwhatkindofmaintenanceis
needed,andthendeterminearegularschedulefor
checkingyoursystem.
Change Change
Changethe the theOil Oil Oil
NOTE: NOTE:
NOTE:Changetheoilafterabreak-inperiodof
200,000–300,000cycles.Afterthebreak-inperiod,
changetheoilonceayear.OrdertwoSilicone-Free
SyntheticISO220EPGearOil(GracoPartNo.
16W645).
1.Placeaminimum2quart(1.9liter)container
undertheoildrainport.Removetheoildrain
plug(G).Allowalloiltodrainfromthedriver.
2.Reinstalltheoildrainplug(G).Torqueto18–23
ft-lb(25–30N•m).
NOTICE NOTICE
NOTICE
Donotover-torque.Thedrainplugcan
becomestrippedanddamaged.
3.Openthe󰘰llcap(P)andaddGracoPartNo.
16W645Silicone-FreeSyntheticISO220EP
GearOil.Checktheoillevelinthesightglass(K).
Filluntiltheoillevelisnearthehalfwaypointof
thesightglass.Theoilcapacityisapproximately
1.–1.2quarts(0.9–1.1liters).Do Do
Donot not notover󰘰ll. over󰘰ll. over󰘰ll.
NOTICE NOTICE
NOTICE
OnlyuseGracoGBLoil(Gracopartnumber
16W645).Anyotheroilmaynotlubricate
properlyandcancausedamagetothedrive
train.
4.Reinstallthe󰘰llcap.
Check Check
CheckOil Oil OilLevel Level Level
Checktheoillevelinthesightglass(K).Theoillevel
shouldbenearthehalfwaypointofthesightglass
whentheunitisnotrunning.Iflow,openthe󰘰llcap
(P)andaddGracoPartNo.16W645Silicone-Free
SyntheticISO220EPGearOilasrequired.Theoil
capacityisapproximately1.0–1.2quarts(0.9–1.1
liters).Do Do
Donot not notover󰘰ll. over󰘰ll. over󰘰ll.
Bearing Bearing
BearingPre Pre Pre- - -Load Load Load
Thebearingpre-loads(R)arefactorysetandarenot
useradjustable.Donotadjustthebearingpre-loads.
3A5124B 9

ErrorCodeTroubleshooting
Error Error
ErrorCode Code CodeTroubleshooting Troubleshooting Troubleshooting
Errorcodescantaketwoforms:
•Alarm: Alarm:
Alarm:Alertsyoutothecauseofthealarmand
shutsdownthedriver.
•Deviation: Deviation:
Deviation:Alertsyoutotheproblem,butthedriver
maycontinuetorunpastthesetlimitsuntilthe
systemabsolutelimitsarereached.
NOTE: NOTE:
NOTE:Theblinkcodeisdisplayedusingthestatus
indicator(L)onthedriver.Theblinkcodegivenbelow
indicatesthesequence.Forexample,blinkcode2
indicatestwoblinks,apause,andthenrepeats.
NOTE: NOTE:
NOTE:Toclearanerrorcode,cyclepowerbyturning
thepowerswitch(S)totheOFFpositionforatleast
30secondsbeforeturningbackON.
Standby Standby
StandbyMode Mode Mode
Whenslowblinkingisdisplayed,thedriverhas
enteredStandbyMode.Whenthedriverison
andpressurizedbutthepumphasnotmovedany
material,thedriverwillenterStandbyMode.
StandbyModewillbeexitedwhen:
•Materialstartstodispenseandcausesthepump
tomove,OR
•Thepressurecontrolknob(N)isadjusted,OR
•Thepowerswitch(S)iscycledOFFandON
Error Error
ErrorCodes Codes CodesTable Table Table
Blink Blink
BlinkCode Code CodeError Error
ErrorType Type TypeTroubleshooting Troubleshooting
TroubleshootingSteps Steps Steps
1AlarmPump Pump
Pumpdiving diving diving
Thepumpisdivingrapidly.Apressureimbalancebetweentheupanddown
strokeofthepumpiscausingthepumptodivewithexcessivespeed.
•Pumpdivingmayoccurwhenthepumprunsoutmaterialwhilesprayingat
highpressure.
•Verifythatmaterialisbeingproperlyfedtothepump.
•Pressurefromthehosecould󰘱owbackintothepumponthedownstroke.
•Verifythatthecheckvalveisinstalledandisproperlyworking.
2AlarmVoltage Voltage
VoltageToo Too TooLow Low Low
•Verifythatlinevoltageiswithintherangespeci󰘰edin
TechnicalSpeci󰘰cations,page27.
•UsetherecommendedcordinPowerSupplyRequirementslistedintheDriver
Installationmanual.
•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.
3AlarmVoltage Voltage
VoltageToo Too TooHigh High High
•Verifythatlinevoltageiswithintherangespeci󰘰edin
TechnicalSpeci󰘰cations,page27.
•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.
4DeviationHigh High
HighTemperature Temperature Temperature
Thetemperatureofthesystemisnearthemaximumoperationtemperature.The
performancehasbeenreducedtopreventthedriverfromcompletelyshutting
down.
•Checkfanoperation.Cleanthefananddriverhousing.
•Reducepressure,dutycycle,orguntipsize.
•Movetheunittoacoolerlocation.
10 3A5124B