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McElroy Acrobat EP800AD, Service Manual

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McElroy Acrobat EP800AD Service Manual Download Page 15

Component Location

s

3 - 2

Component Locations

EP800AD (Acrobat™ HPU)

Hydraulic Fluid 

Filter

Cover Assembly

Feedback Pressure 

Transducer

Control Box

Control Box

Electronic Valve 

Controller

Capacitor

Cover Assembly

Cover Assembly (Control Box Cover Removed)

Summary of Contents for Acrobat EP800AD

Page 1: ...Safety and General Information 1 EP800AD Acrobat HPU SERVICE MANUAL EP800AD Acrobat Hydraulic Power Unit Manual 718601 Rev D 11 19...

Page 2: ......

Page 3: ...d in this manual McElroy Manufacturing Inc reserves the right to make changes at any time without notice or obligation Additional copies of this manual are available When ordering use the part number...

Page 4: ...2 Machine Orientation 2 1 Nameplate Location 2 1 EP800AD Acrobat HPU 2 1 Machine Specification 2 2 Hydraulic Specifications 2 2 Electrical Specifications 2 2 COMPONENT LOCATIONS 3 Component Locations...

Page 5: ...08 240V 50 60Hz 1Ph w Outlets 6 15 Electrical Schematic 721002 Rev A 208 240V 50 60Hz 1Ph w Outlets 6 16 HYDRAULIC 7 Overview 7 1 Components and Functions Hydraulic 7 1 Theory of Operation Hydraulic 7...

Page 6: ...The digital version of this manual has hyperlinks to other portions of the manual After clicking on a hyperlink press Alt left arrow key to return to the page with the hyperlink SAFETY AND GENERAL IN...

Page 7: ...eration or maintenance you choose General Safety Safety is important Report anything unusual that you notice during set up or operation LISTEN for thumps bumps rattles squeals air leaks or unusual sou...

Page 8: ...electrical connections when available Hydraulic Safety It is important to remember that a sudden hydraulic oil leak can cause serious injury or even be fatal if the pressure or oil temperature is high...

Page 9: ...pecifies the exact component Legend for Reference Designators Abbreviations A list of commonly used abbreviations used in this manual are listed below Commonly Used Abbreviations CB1 On Off Switch K1...

Page 10: ...nts for all bolts used refer to the SAE Bolt Torque Value Chart Fastener Usage During any maintenance or repair procedures outlined in this document it is important to salvage all fasteners nuts bolts...

Page 11: ...al number and power requirements The model and serial numbers can be used to register the machine online and activate the warranty Reference Operator s Manual for information on registering your produ...

Page 12: ...Hydraulic Fluid Refer to the Hydraulic Fluids section of this manual 19 482 5mm 12 25 311mm 22 1 562mm Electrical Specifications System Voltage 24VDC Power Requirements 120V 50 60Hz 1Ph 6 5A 0 3HP 120...

Page 13: ...Machine Specifications 2 3 Machine Specifications EP800AD Acrobat HPU This page was intentionally left blank...

Page 14: ...draulic Quick Disconnects Electrical Power Receptacles High Voltage Label Hour Meter Machine and Heater Amperage Label Control Box End Plate Voltage Label Cover Assembly Complete HPU Component Locatio...

Page 15: ...Component Locations EP800AD Acrobat HPU Hydraulic Fluid Filter Cover Assembly Feedback Pressure Transducer Control Box Control Box Electronic Valve Controller Capacitor Cover Assembly Cover Assembly C...

Page 16: ...r Supply Terminal Boards Motor Relay SSR DC Power Fuse Pressure Selection Relay Pressure Selection Relay Heating Pressure Knob Facing Pressure Knob On Off Switch Carriage Switch Pressure Selector Swit...

Page 17: ...ssure Reducing Valve PRV Hydraulic Breather Cap Open Valve Solenoid Close Valve Solenoid Accumulator Dump Valve Hydraulic Manifold Block Pressure Switch DataLogger Port Hydraulic Quick Disconnects Hyd...

Page 18: ...rt DataLogger Port Pressure Control Port Pressure Switch Port Dump Valve Port Carriage Open Port Carriage Close Port Filter to Manifold Port Accumulator Port Gauge and Transducer Port Directional Valv...

Page 19: ...is manual The accumulator may have lost its charge Contact McElroy Technical Support or McElroy Certified Mechanic If the motor is running continuously this means either there is no pressure building...

Page 20: ...low voltage fuse F5 Check PRV valve wiring Remove clean PRV Open Close spool valves Clean with a standard parts cleaner HPU Motor Does Not Run Is main power switch light on when On Off switch is on No...

Page 21: ...ry or death No Check low voltage fuse F5 If a relay is suspected to have failed swap them to verify failure Refer to Theory of Operation Signal Section No Check relays and wiring of switch per Electri...

Page 22: ...e main breaker trips immediately upon resetting visually inspect wiring inside electrical box for damage or a shorting condition Check solenoid resistance solenoid should read around 34 5 Ohms If the...

Page 23: ...ith the motor Replace motor per section HPU Motor and Capacitor Yes There is a problem with the SSR or wiring to the SSR and or motor Inspect wiring for visible damage If this fuse blows there is like...

Page 24: ...al LED on the SSR if the LED responds correctly ON when the heater should be Enabled per the logic explained in section Electrical Receptacles then the control side of the circuit is working correctly...

Page 25: ...e free once both end plates are removed INSTALLATION 1 Position tie rods into left end plate 2 Position left end plate at frame rails and cover assembly 3 Install bolts attaching left end plate to fra...

Page 26: ...d rotate the cover assembly from power pack assembly and rest the cover assembly on its side with the hydraulic filter assembly down INSTALLATION 1 Connect all wires from the cover assembly to the pow...

Page 27: ...power pack assembly to the HPU mounting plate 3 Separate power pack assembly from HPU mounting plate INSTALLATION 1 Position power pack assembly on the HPU mounting plate 2 Install bolts attaching pow...

Page 28: ...me rails A 3 16 drill bit may be used to remove rivets 2 Separate mounting plates from frame rails INSTALLATION 1 Position mounting plates at frame rails 2 Install rivets attaching mounting plates to...

Page 29: ...5 Assembly Disassembly EP800AD Acrobat HPU Torque Specifications Description Torque Handle Tube Bolt 7 ft lb 9 5 Nm Frame Rail Bolt 7 ft lb 9 5 Nm End Plate Acorn Nut 7 ft lb 9 5 Nm Power Pack Assembl...

Page 30: ...y K1 Refer to Electrical Schematic 719904 Sheet B Pressure Switch Senses system pressure It sends a 24VDC signal to close motor relay K1 and turn on the motor when the system pressure is at 830 psi 10...

Page 31: ...Fault Status the controller relays the diagnostic through the LED lights The diagnostic codes are as follows LED STAT LIGHTS 0 475 psi 475 800 psi Module Status Green On Steady Green On Steady Comm S...

Page 32: ...tiometer used to regulate HPU output pressure The switch actuates relays K2 or K3 depending on input potentiometer selection This switch features a sealed washer to prevent water ingress Facing Pressu...

Page 33: ...ght into holder s body to ensure proper electrical contact and water tightness are achieved Ventilation Ventilation is provided by two vents located on the left side of the unit The ventilation plugs...

Page 34: ...toggles on the ON OFF power switch This allows power to the machine components Simultaneously the ON OFF switch light will come on indicating to the user that power is sensed by the unit If power dra...

Page 35: ...aintain system pressure Signal Section Carriage switch S2 places 24VDC on either the open or the close solenoid depending on operator selection When the carriage switch is in neutral no power is place...

Page 36: ...cates a shorted fault if the resistance is more an open fault Open Close Solenoids These solenoids work in much the same way as the PRV solenoid except they are not proportional They are simply fed 24...

Page 37: ...replaced Valve Controller Module Status LED GREEN steady Normal operation RED 1 pulse Output A PRV short detected RED 2 pulses Output B not used short detected GREEN 1 pulses Output A PRV open detecte...

Page 38: ...rom the Motor Install Motor 4 Install the Bearing into the Motor Install the Coupler into the Motor Ensure the Coupler is installed as shown below and aligned properly inside the motor 5 Slide the Mot...

Page 39: ...pressure transducer provides precise analog pressure feedback to the valve controller therefore it is connected downstream of the PRV and cannot be tested on the unit It is non serviceable and should...

Page 40: ...Electrical 6 11 Electrical EP800AD Acrobat HPU This page was intentionally left blank...

Page 41: ...FF SWITCH CB1 SOLID STATE RELAY K1 CHASSIS GROUND POWER SUPPLY PS1 FUSE F1 F2 F3 F4 LINE FILTER LF1 CBx XXA CIRCUIT BREAKER THERMAL CHASSIS GROUND Fx FUSE XA LFx N N P P E LINE FILTER SOLID STATE RELA...

Page 42: ...AD Acrobat HPU Electrical Schematic 719904 Sheet A Rev A 100 120V 50 60Hz 1Ph w Outlets NOTE All wires are 20 AWG unless otherwise noted Reference Illustrations Cover Assembly Control Box Power Pack A...

Page 43: ...AD Acrobat HPU Electrical Schematic 719904 Sheet B Rev A 100 120V 50 60Hz 1Ph w Outlets NOTE All wires are 20 AWG unless otherwise noted Reference Illustrations Cover Assembly Control Box Power Pack A...

Page 44: ...obat HPU Electrical Schematic 721002 Rev A 208 240V 50 60Hz 1Ph w Outlets NOTE All wires are 20 AWG unless otherwise noted Denotes wire splice Reference Illustrations Cover Assembly Control Box Power...

Page 45: ...P800AD Acrobat HPU Electrical Schematic 721002 Rev A 208 240V 50 60Hz 1Ph w Outlets NOTE All wires are 20 AWG unless otherwise noted Reference Illustrations Cover Assembly Control Box Power Pack Assem...

Page 46: ...This is a needle valve that is used to drain the accumulator if the unit is to be serviced In normal operation this valve is turned all the way clockwise to close the path to tank Pressure Control Val...

Page 47: ...filter to a hydraulic accumulator The accumulator supplies pressurized hydraulic fluid 830 1350 psi to a proportional pressure reducing relieving valve The operator sets the facing heating and fusion...

Page 48: ...al for hydraulic fluid recommendations Hydraulic Pump Remove Hydraulic Pump 1 Disassemble the HPU to gain access to the Power Pack Assembly Refer to the Assembly Disassembly section of this manual 2 D...

Page 49: ...om the pump housing Remove the O ring from the cavity on the pump 5 Use a 8mm socket to remove the 4 bolts from the Hydraulic Pump 6 Remove the Hydraulic Pump from the Adapter Plate Remove the O ring...

Page 50: ...dapter Plate Install Hydraulic Pump 1 Install the large return tube with the washers and with a new O ring into the Adapter Plate 2 Install a new O ring onto the Hydraulic Pump Install a new O ring in...

Page 51: ...p O ring on the Pump Install the Fluid Pick up into the pump oriented down tighten the bolt on the clip to secure the Pick up in place 5 Install the Reservoir over the Pump and tubes Install the 4 Res...

Page 52: ...pressure selector control A to fusing pressure 4 Set the fusing pressure reducing knob B to max setting by turning the knob clockwise 5 Turn the EP800AD Acrobat HPU on C and move the carriage directi...

Page 53: ...e the filter should be replaced every 500 hours Ensure the HPU is unplugged from the power source and use a wrench to remove the bowl from the filter housing Remove the old filter cartridge and replac...

Page 54: ...ULIC PUMP QUICK DISCONNECT HYDRAULIC HOSE PRESSURE CONTROL NEEDLE VALVE VALVE DIRECTIONAL CONTROL VALVE CHECK VALVE C HYDRAULIC PUMP QUICK DISCONNECT HYDRAULIC HOSE PRESSURE CONTROL NEEDLE VALVE VALVE...

Page 55: ...PU ASSEMBLY 208 240V 50 60HZ 1PH W CEE 7 7 PLUG HECK R The leader by design McElroy Manufacturing Inc Tulsa Oklahoma U S A NOTE THIS DRAWING AND THE INFORMATION CONTAINED THEREIN IS THE CONFIDENTIAL A...

Page 56: ...back Pressure Transducer MQB00092 Pressure Gauge MEE00073 Pressure Filter Kit MED00097 Pressure Filter Replacement Element MED00099 Accumulator MER00006 Pressure Switch MKP00005 Pressure Control Valve...

Page 57: ...d or damage to the hydraulic components The following table specifies the fluid temperature at various viscosities Temperature rise of the hydraulic fluid can vary from 30 F to about 80 F over the amb...

Page 58: ...revisions outlined here are Revision 1 and Revision 2 Revision 1 Revision 1 of the HPU has a different cover assembly which has the hour meter and DataLogger port on the top of the cover assembly Thi...

Page 59: ...robat HPU Hydraulic Pressure Gauge Hydraulic Manifold 10 Micron Manifold Filter Pressure Switch DataLogger Port Open Valve Dump Valve Close Valve Proportional Pressure Reducing Valve PRV Feedback Pres...

Page 60: ...g Pressure Control Valve Pressure Switch Port Dump Valve Port Carriage Open Port Cartridge Filter Carriage Close Port Accumulator Port Gauge and Transducer Port Directional Valve Port A DMP VLV PRESS...

Page 61: ...l 3 micron hydraulic fluid filter with filter bypass indicator mounted below the accumulator Some Revision 2 HPUs may be equipped with electrical power receptacles 3 Micron Hydraulic Fluid Filter Hour...

Page 62: ...Acrobat HPU Electrical Schematic Revision 1 and 2 719902 Sheet A Rev D 100 120V 50 60Hz 1Ph No Outlets NOTE All wires are 20 AWG unless otherwise noted Reference Illustrations Cover Assembly Control...

Page 63: ...Acrobat HPU Electrical Schematic Revision 1 and 2 719902 Sheet B Rev D 100 120V 50 60Hz 1Ph No Outlets NOTE All wires are 20 AWG unless otherwise noted Reference Illustrations Cover Assembly Control...

Page 64: ...Previous Revisions 8 7 Previous Revisions EP800AD Acrobat HPU Hydraulic Schematic Revision 1 and 2...

Page 65: ...ced every 500 hours To change the 10 micron filter Ensure the HPU is unplugged from the power source and remove the plug on the manifold block Remove the old filter and replace with a new filter Insta...

Page 66: ...ro pressure is shown on the carriage pressure gauge F 8 Turn the EP800AD Acrobat HPU off C 9 Refill the hydraulic reservoir according to procedure Check Hydraulic Fluid in this manual 10 Disconnect th...

Page 67: ...t www mcelroy com Part Description Part Number Feedback Pressure Transducer MQB00092 Pressure Gauge MEE00067 Pressure Filter Kit MED00097 Pressure Filter Replacement Element MED00099 Accumulator MER00...

Page 68: ...1 relay 24VDC connector See Electrical Schematic 719904 Fuse F1 5A Check for continuity check fuse holder is screwed on tight A motor running for longer than 10 seconds check hydraulic system not maki...

Page 69: ...r receptacle is controlled through the SSR wiring harness Check that the SSR wiring harness is hooked up properly per Electrical Schematic 719904 Sheet B 10 Place the Carriage Switch in the Close posi...

Page 70: ...19 Cycle the carriage open and close a few times ensuring that the switch position corresponds to the carriage direction of movement Troubleshooting Check wiring inside box refer to Electrical Schema...

Page 71: ...Notes 10 1 Notes EP800AD Acrobat HPU NOTES Notes...

Page 72: ......

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