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

ErrorCodeTroubleshooting
Blink Blink
BlinkCode Code CodeError Error
ErrorType Type TypeTroubleshooting Troubleshooting
TroubleshootingSteps Steps Steps
5DeviationLow Low
LowTemperature Temperature Temperature
•Warmequipment.
6AlarmMotor Motor
MotorTemperature Temperature TemperatureFault Fault Fault
Motorisrunningtoohot.Allowunittocool.
•Checkfanoperation.Cleanthefananddriverhousing.
•Reducepressure,dutycycle,orguntipsize.
•Movetheunittoacoolerlocation.
7AlarmBoard Board
BoardTemperature Temperature TemperatureFault Fault Fault
Thecontrolboardisrunningtoohot.Allowtheunittocool.
•Checkfanoperation.Cleanthefananddriverhousing.
•Reducepressure,dutycycle,orguntipsize.
•Movetheunittoacoolerlocation.
8AlarmEncoder Encoder
EncoderCalibration Calibration CalibrationError Error Error
•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.
•Calibratetheencoder(thiscodewillblinkifcalibrationisinprogress).
•SeeGraco Graco
GracoContact Contact ContactInformation Information Information(GracoExtendedWarranty,page28).
9AlarmEncoder Encoder
EncoderError Error Error
•Cyclepowerandcheckthestatusindicator(L)toseeiftheerrorisstillactive.
•Verifythattheencodercable(EE)isconnectedsecurely(see
WiringSchematic,page26).
•Theencodermayneedreplacement.
•SeeGraco Graco
GracoContact Contact ContactInformation Information Information(GracoExtendedWarranty,page28).
10AlarmSoftware Software
SoftwareVersions Versions VersionsDo Do DoNot Not NotMatch Match Match
•Seethesystemmanualforsoftwaretokenpartnumber.
•ObtainsoftwareupdatetokenandfollowSoftware Software
SoftwareUpdate Update Updateprocedure.
11AlarmCircuit Circuit
CircuitBoard Board BoardCommunication Communication CommunicationFailure Failure Failure
•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.
•SeeGraco Graco
GracoContact Contact ContactInformation Information Information(GracoExtendedWarranty,page28).
12AlarmInternal Internal
InternalCircuit Circuit CircuitBoard Board BoardHardware Hardware HardwareFailure Failure Failure
•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.
•SeeGraco Graco
GracoContact Contact ContactInformation Information Information(GracoExtendedWarranty,page28).
13,14AlarmInternal Internal
InternalSoftware Software SoftwareError Error Error
•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.
•SeeGraco Graco
GracoContact Contact ContactInformation Information Information(GracoExtendedWarranty,page28).
SlowBlinkDeviationSeeStandbyMode,page10.
3A5124B
11

Repair
Repair Repair
Repair
Toavoidelectricshock,󰘰reandexplosionhazard,
and/orinjuryfrommovingpartshazard,turnoff
equipmentpowerandshutoffpoweratthemain
circuitbreakerbeforerepairing.Wearappropriate
protectiveequipmentwheninworkarea.Wait󰘰ve
minutesbeforeservicing.
Makesurenowiresarepinchedwhenre-installing
covers.Wireswillbedamagedandcreatean
electricalhazardand/or󰘰reandexplosionhazard
ifpinched.
NOTE: NOTE:
NOTE:ConsultGracoTechnicalAssistanceoryour
Gracodistributorforgenuinereplacementfasteners.
M8x30socket-headcapscrewsofClass12.9steel
orbetterwithaminimumyieldstrengthof1100MPa
(160,000psi)areacceptablealternatives.
Replace Replace
ReplaceOutput Output OutputSeal Seal SealCartridge Cartridge Cartridge
1.Stopthepumpatthebottomofitsstroke.Shut
offandlockoutpowertothedriver.
2.FollowthePressureReliefProcedure,page8.
3.Disconnectthelowerfromthedriver,as
explainedinyourseparatesystemmanual.
4.Draintheoilfromthedriver.See
ChangetheOil,page9.
5.Reinstalltheoildrainplug.Torqueto18–23ft-lb
(25–30N•m).
6.Unscrewtheoutputcartridge(19)fromthedriver.
SeeParts,page22.
7.Installthenewoutputcartridge.Torqueto
175–200ft-lb(240–280N•m).
8.Fillwithoil.SeeChangetheOil,page9.
9.Reconnectthelowertothedriver.
10.Turnonpowerandresumeoperation.
12
3A5124B

Repair
Software Software
SoftwareToken Token TokenUpdate Update Update
Tohelpprevent󰘰reandexplosion,donot
connect,download,orremovethetokenunless
theunitisremovedfromthehazardous(explosive
atmosphere)location.
1.TurnthedisconnectswitchOFF.Removepower
fromtheunit.
2.Usea6mmAllenwrenchtoremovefourbolts.
Removethemotorcover.
3.Insertandpressthetoken󰘰rmlyintothetoken
connectorslot.NOTE: NOTE:
NOTE:Thetokenrequiresno
speci󰘰corientation.
4.Reinstallthemotorcover.
5.ApplypowerandturnthedisconnectswitchON.
6.MonitortheStatusIndicatorLight(L)forthe
statusofthesoftwareupdate.
a.TheStatusIndicatorLightwillblinkslowlyfor
afewsecondsandthenrapidlyforseveral
seconds.
b.Oncetheupdateiscomplete,theunit
willpowerupand󰘱ashoutthesoftware
version.Threenumberswillbe󰘱ashed
outtoconveythesoftwareversionin
theformatofx.yy.zzz.Forexample:
“󰘱ash-pause-󰘱ash-󰘱ash-pause-󰘱ash-pause”
wouldindicatethatsoftwareversionis
1.02.001installed.
7.Theunitwill󰘱ashoutthesoftwareversionevery
timetheunitispoweredupwhilethesoftware
tokenispresent.Thetokencanremaininplace
evenafterthesoftwarehasbeenupdated,but
canoptionallyberemoved.
8.Thelatestsoftwareversionforeachsystemcan
befoundatTechnicalSupportatwww.graco.com
underthe“FAQ”section.
3A5124B 13

Repair
Control Control
ControlBoard Board BoardReplacement Replacement Replacement
(25C187) (25C187)
(25C187)
NOTICE NOTICE
NOTICE
Toavoiddamagetotheelectriccomponents,wear
groundingstrap(GracoPartNo.112190–not
supplied)andgroundappropriately.
Overview Overview
Overview
Themaincontrolboardassemblymanagesthe
operationofthedriver.Itispermanentlyattached
totheelectronicscover.
Tools Tools
ToolsRequired Required Required
•6mmHexWrench
•PhillipsScrewdriver(#1)
•TorqueWrench(15ft-lb,20N•m)
Prepare Prepare
PrepareDriver Driver Driver
1.Removepowerfromthedriver.Follow
appropriatelock-out/tag-outprocedures.Wait
󰘰veminutesbeforeservicing.
2.FollowthePressureReliefProcedure,page8.
3.Decouplethepumplowerfromthedriverperthe
systemmanual.
Disconnect Disconnect
DisconnectPower Power PowerWires Wires Wires
1.Removethescrews(J)andjunctionboxcover
(Z)fromtheelectricaljunctionbox(Y).Remove
screw(Ys)andsleevehousing.
2.DisconnectwiresfromterminalbushingsL1and
L2.
3.Removethegroundluganddisconnectthegreen
groundwire.
4.Disconnectwiresfromtheoppositesideofthe
disconnectinterminalslabeled2T1and4T2.
14
3A5124B

Repair
Remove Remove
RemoveElectronics Electronics ElectronicsCover Cover Cover
NOTICE NOTICE
NOTICE
Toavoidequipmentdamage,carefullysupportthe
coverwhenremovingthelastbolt.Holdthecover
horizontallyandtakecarethatthewiresarenot
pulledtight.
1.Removethe12bolts(CB)thatholdonthe
electronicscoverusinga6mmhexwrench.
Placeboltsinasafelocation.
2.Pullthecoverstraightoffofthealignmentpins
thatholdthecoverinplace.
3.Supportthecoverafterithasbeenremovedto
preventputtingexcessstrainonthewiresinside.
Disconnect Disconnect
DisconnectControl Control ControlBoard Board Board
NOTE: NOTE:
NOTE:Thecontrolboardisinsidetheelectronics
cover.Toreplacethecontrolboardtheentire
electronicscovermustbereplaced.
1.Todisconnectthecontrolboardunplug
allconnectorsfromthecontrolboard(see
WiringSchematic,page26).
2.Removemotorwiresfromclipinsidehousing
(seeWiringSchematic,page26).
3.Settheelectronicscover/controlboardaside.
Reinstall Reinstall
ReinstallElectronics Electronics ElectronicsCover Cover Coveronto onto ontoDriver Driver Driver
Makesurenowiresarepinchedwhenre-installing
covers.Wireswillbedamagedandcreatean
electricalhazardand/or󰘰reandexplosionhazard
ifpinched.
1.Pluginallconnectors.Ensureallconnectors
aresecurelyattachedtothecontrolboard.See
WiringSchematic,page26.
2.Secureloosemotorwiresintotheclipinsidethe
housing(seeWiringSchematic,page26).
3.Reinstallelectronicscoverontocenterhousing.
4.Installthe12boltsusinga6mmhexwrench.
NOTE: NOTE:
NOTE:Ensurethelockwashersarestillinplace.
5.Torquetheboltsto15ft-lb(20N•m).
Power Power
PowerUnit Unit Unit— — —Run Run RunCalibration Calibration CalibrationProcedure Procedure Procedure
NOTE: NOTE:
NOTE:Thedrivermustbede-coupledfromthelower
andmustbeabletocyclefreelywithnoobstructions.
1.Cyclepowertothedriverby󰘰rstturningthe
powerswitch(S)OFF,andthenONagain.
2.WaitforthestatusindicatorLED(L)toturnon
solidorstartblinking.
3.Within30seconds,rapidlyturnthepressure
controlknob(N)backandforthfrom0to10at
least󰘰vetimesandthensettheknobbackto0.
IfthestatusindicatorLED(L)wassolidbefore,
itwillbeginblinkinganencodercalibrationerror
(code8)duringthecalibrationprocess.
4.Thedriveroutputshaft(H)willrunupanddown
slowlyoverthecourseofseveralminutes.
5.Midwaythroughtheauto-calibrationprocessthe
driveroutputshaft(H)willpauseasitmovesto
thenextstep.
6.Thedriveroutputshaft(H)willmoveupand
downfaster5–6times.
7.Ensuretheauto-calibrationprocessiscomplete
beforecontinuing(waitfortheLEDtostop
blinking).
Reattach Reattach
ReattachPump Pump PumpLower Lower Lower
Seethesystemmanual.
3A5124B 15

Repair
Encoder Encoder
EncoderReplacement Replacement Replacement(25C169) (25C169) (25C169)
NOTICE NOTICE
NOTICE
Toavoiddamagetotheelectroniccomponents,
weargroundingstrap(GracoPartNo.112190)
andgroundappropriately.
Overview Overview
Overview
Theencoderisusedbythedriverfortwopurposes.
First,theencodertellsthecontrolboardwherethe
motorisinitsmechanicalrotationandusesthat
informationtoproperlycontrolthemotortorque.
Second,itcontrolsstrokelengthbyallowingthe
controlboardtocountthenumberofcompletemotor
rotations.
Tools Tools
ToolsRequired Required Required
•6mmHexWrench
•.050inHexWrench
•PhillipsScrewdriver(#1)
•TorqueWrench(15ft-lb,20N•m)
•Blue(medium)threadlockingcompound
Prepare Prepare
PrepareDriver Driver Driver
1.Removepowerfromthedriver.Follow
appropriatelock-out/tag-outprocedures.Wait
󰘰veminutesbeforeservicing.
2.FollowthePressureReliefProcedure,page8.
3.Decouplethepumplowerfromthedriverperthe
systemmanual.
Remove Remove
RemoveElectronics Electronics ElectronicsCover Cover Cover(When (When (WhenAlso Also Also
Replacing Replacing
Replacingthe the theEncoder Encoder EncoderCable) Cable) Cable)
NOTICE NOTICE
NOTICE
Toavoidequipmentdamage,carefullysupportthe
coverwhenremovingthelastbolt.Holdthecover
horizontallyandtakecarethatthewiresarenot
pulledtight.
1.Removethe12bolts(CB)thatholdonthe
electronicscoverusinga6mmhexwrench.
Placeboltsinasafelocation.
2.Pullthecoverstraightoffofthealignmentpins
thatholdthecoverinplace.
3.Supportthecoverafterithasbeenremovedto
preventputtingexcessstrainonthewiresinside.
16 3A5124B

Repair
Remove Remove
RemoveMotor Motor MotorCover Cover Cover
1.Removethe4boltsthatholdonthemotorcover
usinga6mmhexwrench.Placeboltsinasafe
location.
2.Setmotorcoveraside.
Remove Remove
RemoveEncoder Encoder Encoder
1.Ifreplacingtheencodercablealso,unplugthe
encodercable(AE/AF)fromthecontrolboardand
theencoderandremove.
2.Loosenthe2hubsetscrews(AA)usingthe
included.050”hexwrench.
3.Removethe2mountingscrews(AC)witha
Phillipsheadscrewdriver.
4.Pullencoder(AB)offofrotorshaft.
NOTE: NOTE:
NOTE:Thisprocedureonlyrequirestheremovalof
the2Phillipsheadmountingscrews.Allotherbolts
shouldremaininplace.
AASetscrews
5
50+/-5in-oz(0.35
N•m).
ABEncodermounting󰘱ange
ACPhillipsheadmountingscrews
ADRotorBearingHousing
Install Install
InstallNew New NewEncoder Encoder Encoder
1.Ifreplacingtheencodercable(AE/AF)also,
placetheencoderconnectorcablethroughthe
motorhousing.
NOTE: NOTE:
NOTE:Theencoderconnector(AE)endisthe
smallerofthetwoconnectors.
AEEncoderconnector(smaller)
AFControlboardconnector(larger)
2.Slidethenewencoderontotherotorshaft.
3.Applyasmallamountofblue(medium)thread
lockertothe2Phillipsheadmountingscrews
(AC)andsecureencodermounting󰘱ange(AB)
tomotorhousing(AD).
4.Removethe2setscrews(AA)fromtheencoder
hubusingtheincluded.050in.hexwrench.
5.Applyasmallamountofblue(medium)thread
lockertothesetscrews(AA)andscrewbackinto
theencoder.Tightento50+/-5in-oz(0.35N•m).
6.Plugencodercableintotheencoder(AE).If
theencodercablewasalsoreplaced,plug
theotherendintothecontrolboard(AF).See
WiringSchematic,page26.
3A5124B
17

Repair
Reinstall Reinstall
ReinstallElectronics Electronics ElectronicsCover Cover Coveronto onto ontoDriver Driver Driver(only (only (only
if if
ifremoved removed removedto to toreplace replace replacethe the theencoder encoder encodercable) cable) cable)
Makesurenowiresarepinchedwhenre-installing
covers.Wireswillbedamagedandcreatean
electricalhazardand/or󰘰reandexplosionhazard
ifpinched.
1.Pluginallconnectors.Ensureallconnectors
aresecurelyattachedtothecontrolboard(see
WiringSchematic,page26).
2.Secureloosemotorwiresintotheclipinsidethe
housing(seeWiringSchematic,page26).
3.Reinstallelectronicscoverontocenterhousing.
4.Installthe12boltsusinga6mmhexwrench.
NOTE: NOTE:
NOTE:Ensurethelockwashersarestillinplace.
5.Torquetheboltsto15ft-lb(20N•m).
Reinstall Reinstall
ReinstallMotor Motor MotorCover Cover Cover
1.Reinstallmotorcoverontodriverhousing.
2.Installthefourboltsandmountinglockwashers
thatholdonthemotorcoverusinga6mmhex
wrench.Ensurethelockwashersarestillin
place.
3.Torquetheboltsto15ft-lb(20N•m).
4.FollowthePowerUnit—RunCalibration
Procedure,page15.
Reattach Reattach
ReattachPump Pump PumpLower Lower Lower
Seethesystemmanual.
18 3A5124B

Repair
Position Position
PositionSensor Sensor SensorReplacement Replacement Replacement
(24W120) (24W120)
(24W120)
NOTICE NOTICE
NOTICE
Toavoiddamagetotheencoderandcontrolboard,
weargroundingstrap(GracoPartNo.112190–
notsupplied)andgroundappropriately.
Overview Overview
Overview
Thepositionsensorisusedtodeterminewherethe
driveroutputshaft(H)isinthestroke.
Tools Tools
ToolsRequired Required Required
•6mmHexWrenches
•13mmOpen-EndedWrench
•6mmOpen-EndedWrench
•PhillipsScrewdriver(#2)
•TorqueWrench(15ft-lb,20N•m)
Prepare Prepare
PrepareDriver Driver Driver
1.Removepowerfromthedriver.Follow
appropriatelock-out/tag-outprocedures.Wait
󰘰veminutesbeforeservicing.
2.FollowthePressureReliefProcedure,page8.
3.Decouplethepumplowerfromthedriverperthe
systemmanual.
Remove Remove
RemoveElectronics Electronics ElectronicsCover Cover Cover
NOTICE NOTICE
NOTICE
Toavoidequipmentdamage,carefullysupportthe
coverwhenremovingthelastbolt.Holdthecover
horizontallyandtakecarethatthewiresarenot
pulledtight.
1.Removethe12bolts(CB)thatholdonthe
electronicscoverusinga6mmhexwrench.
Placeboltsinasafelocation.
2.Pullthecoverstraightoffofthealignmentpins
thatholdthecoverinplace.
3.Supportthecoverafterithasbeenremovedto
preventputtingexcessstrainonthewiresinside.
3A5124B 19

Repair
Remove Remove
RemovePosition Position PositionSensor Sensor Sensor
1.Unplugthepositionsensor(AR)fromthecontrol
board(seeWiringSchematic,page26).
2.Loosenthepositionsensorjamnut(AS)using
a13mmwrench.
3.Unscrewthepositionsensor(AR)fromthecenter
housingusinga6mmopenendedwrench.
NOTE: NOTE:
NOTE:Allowwirestorotatewithpositionsensor
topreventtwisting.
Install Install
InstallNew New NewPosition Position PositionSensor Sensor Sensor
1.Carefullyscrewthereplacementpositionsensor
intothecenterhousing.
NOTE: NOTE:
NOTE:Becarefulnottodamagethewires.The
wireswillhavetoberotatedwhiletheposition
sensorisinstalledtopreventthemfrombeing
twisted.
2.Usethe6mmwrenchtocompletetheinstallation
ofthepositionsensor.Becarefulnottouse
excessivetorque.Stoponcethepositionsensor
bottomsoutinthebore.
NOTICE NOTICE
NOTICE
Donotovertightenthepositionsensor.
Damagetothepositionsensormayresult.
3.Tightenthejamnutonthepositionsensor󰘰nger
tight.
NOTICE NOTICE
NOTICE
Donotuseawrenchtotightenthejamnut.
Damagetothepositionsensormayresult.
4.Plugthepositionsensorintothecontrolboard
(seeWiringSchematic,page26).
5.Resetthedipswitch.
Reinstall Reinstall
ReinstallElectronics Electronics ElectronicsCover Cover Coveronto onto ontoDriver Driver Driver
Makesurenowiresarepinchedwhenre-installing
covers.Wireswillbedamagedandcreatean
electricalhazardand/or󰘰reandexplosionhazard
ifpinched.
1.Pluginallconnectors.Ensureallconnectors
aresecurelyattachedtothecontrolboard.See
WiringSchematic,page26.
2.Secureloosemotorwiresintotheclipinsidethe
housing(seeWiringSchematic,page26).
3.Reinstallelectronicscoverontocenterhousing.
4.Installthe12boltsusinga6mmhexwrench.
NOTE: NOTE:
NOTE:Ensurethelockwashersarestillinplace.
5.Torquetheboltsto15ft-lb(20N•m).
Reattach Reattach
ReattachPump Pump PumpLower Lower Lower
Seethesystemmanual.
20 3A5124B