ep800ad (acrobat™ hydraulic power unit) service manualjul 07, 2016 · using the service manual...

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1 EP800AD (Acrobat™ HPU)

SERVICE MANUAL

EP800AD (Acrobat™ Hydraulic Power Unit)

Manual: 718601 Rev D 11/19

This manual contains information and procedures that are intended for experienced service technicians. Study and understand these procedures thoroughly before servicing or repairing the machine. Do not attempt any service which you do not fully understand, or cannot be done safely with the tools and equipment available to you. Failure to do so could result in personal injury or equipment damage.

There may be components which are not user-serviceable. If you have questions or encounter a issue that you do not understand or cannot solve, contact McElroy Technical Services at 918-831-9224 or [email protected].

Service training is available from McElroy University at www.mcelroy.com/university.

The instructions, illustrations and specifications in this manual are based on the latest information available at the time of publication. Your machine may have product improvements and options not yet contained 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 on the front cover.

McElroy, McElroy Logo, are trademarks of McElroy Manufacturing, Inc. in the U.S. and/or other countries.

This document may contain portions of technical materials of various suppliers. Such component suppliers shall not be responsible for the direct results of their technical materials being presented out of context.

Designations used by component suppliers to distinguish their products which appear in this manual are the property of the respective trademark owner(s). McElroy is aware of the following component suppliers trademarks.

No part of this manual may be reproduced in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval systems, without the

express written consent of McElroy Manufacturing, Inc.

Copyright 2019, 2018, 2017 McElroy Manufacturing, Inc.All rights reserved.P.O. Box 580550

Tulsa, Oklahoma 74158-0550, USA

TABLE OF CONTENTSSAFETY AND GENERAL INFORMATION 1Using the Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1Read and Understand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2Do Not Modify Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3Hydraulic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3Disconnect Machine Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4Reference Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5SAE Bolt Torque Value Chart (Grade 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5Fastener Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

MACHINE SPECIFICATIONS 2Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1Nameplate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1EP800AD (Acrobat™ HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1Machine Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2Hydraulic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

COMPONENT LOCATIONS 3Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1Complete HPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3Power Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4Hydraulic Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

TROUBLESHOOTING 4HPU Motor Does Not Shut Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1HPU Motor Does Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2No Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2Pressure Control Is Not Stable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3Pressure Selector Switch Not Functioning (selecting between pressure control knobs) . . . . . . . . . . . . . 4 - 3Open/Close Switch Not Functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4Main Circuit Breaker Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4Fuse F5 Blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5Fuse F1/F3 Blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5Fuse F2/F4 Blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5

Heater Receptacle Not Functioning Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6Oil Foams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6Quick Disconnects Leaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6

ASSEMBLY/DISASSEMBLY 5Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1End Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2Power Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3Mounting Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

ELECTRICAL 6Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1Components and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1Theory of Operation (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12Electrical Schematic (719904) Sheet A, Rev A 100-120V, 50/60Hz, 1Ph w/ Outlets . . . . . . . . . . . 6 - 13Electrical Schematic (719904) Sheet B, Rev A 100-120V, 50/60Hz, 1Ph w/ Outlets. . . . . . . . . . . . 6 - 14Electrical Schematic (721002) Rev A 208-240V, 50/60Hz, 1Ph w/ Outlets . . . . . . . . . . . . . . . . 6 - 15Electrical Schematic (721002) Rev A 208-240V, 50/60Hz, 1Ph w/ Outlets . . . . . . . . . . . . . . . . 6 - 16

HYDRAULIC 7Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1Components and Functions (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1Theory of Operation (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12

PREVIOUS REVISIONS 8Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1Revision 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1Revision 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4Electrical Schematic Revision 1 and 2 (719902) Sheet A, Rev D 100-120V, 50/60Hz, 1Ph, No Outlets . . 8 - 5Electrical Schematic Revision 1 and 2 (719902) Sheet B, Rev D 100-120V, 50/60Hz, 1Ph, No Outlets . . 8 - 6Hydraulic Schematic (Revision 1 and 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7Service and Repair (Revision 1 and 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10

POST SERVICE FUNCTION CHECKS 9Post Service Function Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1

NOTES 10Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1

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1 - 1Safety and General Information EP800AD (Acrobat™ HPU)

Using the Service ManualThis manual provides information and service procedures based upon current machine knowledge and configuration at the time the manual was written. The instructions, illustrations and specifications are based on the latest information available at the time of publication. Due to ongoing efforts to continuously improve the equipment, there may be changes on the machine not yet reflected in this manual.

McElroy Manufacturing, Inc. reserves the right to make changes at any time without notice or obligation.

Procedures given in this manual provide one method for completing a given task. Additional information may be available through McElroy Technical Services.

Additional copies of this manual are available. When ordering, use the part number on the front cover.

Operating instructions are found in the Acrobat™ 160, 180 and 250 Fusion Machines Operator’s Manual.

Section titles are located on the edge of the page to aid in locating information.

IMPORTANT: 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 INFORMATION

Safety AlertsGeneral safety messages appear in this section of the manual. Specific safety messages are located in the applicable sections of the manual where a potential hazard may occur if the instructions or procedures are not followed.

You will see the hazard alert sign with these words: DANGER, WARNING, and CAUTION.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

In this manual you should look for two other words: NOTICE and IMPORTANT.

NOTICE: can keep you from doing something that might damage the machine or someone’s property. It may also be used to alert against unsafe practices.

IMPORTANT: can help you do a better job or make your job easier in some way.

Warranty

McElroy Warranty

McElroy 5 year limited warranty is printed inside the Operator’s Manual.

¡PELIGRO!

¡ATENCIÓN!

¡CUIDADO!

ОСТОРОЖНО

ATTENTION

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1 - 2 Safety and General InformationEP800AD (Acrobat™ HPU)

Read and UnderstandDo not operate this equipment until you have carefully read, and understand all the sections of this manual, and all other equipment manuals that will be used with it.

Your safety and the safety of others depends upon care and judgment in the operation of this equipment.

Follow all applicable federal, state, local, and industry specific regulations.

McElroy Manufacturing, Inc. cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this manual and on the machine are therefore not all inclusive. You must satisfy yourself that a procedure, tool, work method, or operating technique is safe for you and others. You should also ensure that the machine will not be damaged or made unsafe by the method of operation or maintenance you choose.

General SafetySafety is important. Report anything unusual that you notice during set up or operation.

LISTEN for thumps, bumps, rattles, squeals, air leaks, or unusual sounds.

SMELL odors like burning insulation, hot metal, burning rubber, hot oil, or natural gas.

FEEL any changes in the way the equipment operates.

SEE problems with wiring and cables, hydraulic connections, or other equipment.

REPORT anything you see, feel, smell, or hear that is different from what you expect, or that you think may be unsafe.

Safety EquipmentWear a hard hat, safety shoes, safety glasses, and other applicable personal protective equipment.

Remove jewelry and rings, and do not wear loose-fitting clothing or long hair that could catch on controls or moving machinery.

Ensure shop has proper fire prevention and fire-fighting and that all personnel know how and when to use it.

Do Not Modify MachineMake no modifications to your equipment unless specifically recommended or requested by McElroy.

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1-92

ДУМАЙТЕ О

БЕЗОПАСНОСТИ В ПЕРВУЮ ОЧЕРЕДЬ

PENSEZ Sécurité

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Disconnect Machine Before ServicingDisconnect the machine from power before servicing, cleaning, repairing, or transporting machine.

Electrical SafetyAlways ensure equipment is properly grounded. It is important to remember that if you are working in a wet environment with electrical devices. Proper ground connections help to minimize the chances of an electric shock.

Frequently inspect electrical cords and unit for damage. Have damaged components replaced and service performed by a qualified electrician.

Do not carry electrical devices by the cord

NOTICE: Always connect units to the proper power source as listed on the unit, or in the owner’s manual. Use GFCI electrical connections when available.

Hydraulic SafetyIt 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 enough.

Escaping fluid under pressure can penetrate the skin causing serious injury. Keep hands and body away from pinholes which eject fluid under pressure. Use a piece of cardboard or paper to search for leaks. If any fluid is injected into the skin, it must be immediately removed by a doctor familiar with this type of injury.

Unwanted movement of the machine could result in serious injury or damage to machine. Unwanted movement of the machine may take place if switches do not match machine state when the machine power is turned on.

NOTICE: Wear safety glasses, and keep face clear of area when bleeding air from hydraulic system to avoid spraying oil into eyes.

¡ATENCIÓN!

¡ATENCIÓN!

WR0

0055

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-93

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30-9

2W

R000

78-4

-8-9

3

¡ATENCIÓN!

¡ATENCIÓN!

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1 - 4 Safety and General InformationEP800AD (Acrobat™ HPU)

Replacement PartsRefer to the McElroy parts finder at www.mcelroy.com to locate parts for purchase. Reference the model number on the nameplate of the machine when using the parts finder.

Contact your customer service representative to order replacement parts.

Reference DesignatorsReference Designators are assigned to components shown on the schematics and other reference diagrams. Each code-like designator identifies a specific component. The designator is comprised of an uppercase letter(s) followed by a number. The letters identify the type of component and the number specifies the exact component.

Legend for Reference Designators

AbbreviationsA list of commonly used abbreviations used in this manual are listed below.

Commonly Used Abbreviations

CB1 On/Off SwitchK1 Motor RelayK2 RelayK3 RelayLF1 Line FilterPS1 Power SupplyR1 Facing Pressure RegulatorR2 Heating Pressure RegulatorR3 Fusing Pressure RegulatorS1 Pressure Selector SwitchS2 Carriage SwitchF1 Motor Fuse for 120VAC/220VACF2 Power Supply Fuse for 120VAC/220VACF3 Motor Fuse for 220VACF4 Power Supply Fuse for 220VACF5 DC Power Fuse

HPU Hydraulic Power UnitPSI Pounds per Square InchPRV Proportional Pressure Reducing ValveVDC Voltage Direct CurrentVAC Voltage Alternating CurrentLED Light Emitting DiodeCOMM CommunicationsIEC International Electromechanical CommissionSSR Solid State RelayQD Quick DisconnectEVC Electronic Valve Controller

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Fastener IdentificationSAE bolt strength grades range from grade 2 to grade 8. The larger the value of the grade number, the greater the strength of the bolt. Identification of a bolt is determined by the arrangement of line marks on the top of each bolt head. The strength grade of each bolt corresponds to the number of line marks on top of the bolt head plus 2. The higher the value of the class number, the greater the bolt strength. All bolts used in the assembly of the EP800AD (Acrobat HPU) are SAE Grade 5 bolts. For help identifying torque requirements for all bolts used, refer to the SAE Bolt Torque Value Chart.

Fastener UsageDuring any maintenance or repair procedures outlined in this document, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. During reassembly it is important to use retaining compound where referenced on the assembly drawing or assembly procedure. Drawings and assembly procedures can be found in this document and at:

www.mcelroy.com

SAE Bolt Torque Value Chart (Grade 5)

Bolt Size Torque, ft-lb Torque, N•m

1/4-20 9 7

1/4-28 12 9

5/16-18 20 15

5/16-24 23 17

3/8-16 40 30

3/8-24 40 30

7/16-14 60 45

7/16-20 65 50

1/2-13 95 70

1/2-20 100 75

9/16-12 135 100

9/16-18 150 110

5/8-11 180 135

5/8-18 210 155

3/4-10 325 240

3/4-16 365 270

Grade 2

Grade 5

Grade 8

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2 - 1 Machine SpecificationsEP800AD (Acrobat™ HPU)

MACHINE SPECIFICATIONS

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5Nameplate LocationEvery unit has a name plate that includes the machine’s model number, serial 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 product.

Machine OrientationLeft, right, front, and rear of the machine are noted from the perspective of an operator standing in front of the electrical box.

Nameplate

EP800AD (Acrobat™ HPU)

FRONT

REAR

LEFT

RIGHT

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2 - 2Machine Specifications EP800AD (Acrobat™ HPU)

Machine SpecificationMachine Length: 22.1" (562 mm)

Machine Width: 12.25" (311 mm)

Machine Height: 19" (482.5 mm)

Machine Weights: 56 lbs (25.4 Kg)

Hydraulic SpecificationsReservoir Filling Capacity: 0.375 gal (1.41 liters)

Hydraulic Pressure: 800 psi max. fusion pressure

Hydraulic Fluid: Refer to the Hydraulic Fluids section of this manual.

19"(482.5mm)

12.25"(311mm)

22.1"(562mm)

Electrical SpecificationsSystem Voltage: 24VDC

Power Requirements: 120V, 50/60Hz, 1Ph, 6.5A, 0.3HP (120V package), 208-240V, 50/60Hz, 1Ph, 4.5A, 0.3HP (240V package)

Fuses: F1 3.15 Amp Motor Protection 120VAC and 220VAC

F2 2.5 Amp Power Supply Protection 120VAC and 220VAC

F3 3.15 Amp Motor Protection 220VAC

F4 2.5 Amp Power Supply Protection 220VAC

F5 3 Amp Protect VDC circuitry fed from Power Supply

22.1"(562mm)

12.25"(311mm)

19"(482.5mm)

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2 - 3 Machine SpecificationsEP800AD (Acrobat™ HPU)

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3 - 1Component Locations EP800AD (Acrobat™ HPU)

COMPONENT LOCATIONS

Bypass Filter Indicator

End Plate

Hydraulic Pressure Gauge

Handle Tube

McElroy Branding Label

McElroy Branding Label

Electrical Receptacle Label

Hydraulic 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 LocationsThe components of the HPU outlined in this section reflect the latest revision of the machine. For information on component functions and locations on HPUs of previous revisions, refer to section Previous Revisions in this manual.

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3 - 2 Component LocationsEP800AD (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)

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Motor Fuse

Fusing Pressure Knob

Line Filter

Power Supply

Terminal Boards

Motor Relay (SSR)

DC Power Fuse

Pressure Selection

Relay

Pressure Selection

Relay

Heating Pressure Knob

Facing Pressure KnobOn/Off Switch

Carriage Switch

Pressure Selector SwitchMotor Fuse

Power Supply Fuse

Power Supply Fuse

F1

CB1

LF1

PS1

S2

R1

R2

R3

K1

F5

K3

K2

S1

F2

F3

F4

Control Box

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3 - 4 Component LocationsEP800AD (Acrobat™ HPU)

Proportional Pressure Reducing

Valve (PRV)

Hydraulic Breather Cap

Open Valve Solenoid

Close Valve Solenoid

Accumulator

Dump Valve

Hydraulic Manifold Block

Pressure Switch

DataLogger® Port


Hydraulic Check/Fill

Plug

Pressure Relief

Hydraulic Drain Plug

Power Pack Assembly

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pone

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Manifold to Filter Port

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 Valve Port

F1

TR

A

F0

DMP VLV

PRESS CNTRL

PS SWACC

G

DIR VLV

B


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4 - 1 TroubleshootingEP800AD (Acrobat™ HPU)

TROUBLESHOOTING

HPU Motor Does Not Shut Off

Is the black dump valve knob fully closed?

No: • Close it tightly clockwise.

Does the unit have adequate hydraulic fluid level?

No: • Add hydraulic fluid. Refer to the Hydraulic Fluid section of this manual for fluid recommendations.

Does the unit run much longer than it should and/or have a very short cycle time?

Yes: • Normal cycle time is on for 5 - 7 seconds and off for 30+ seconds (depending on temperature). If the cycle time is much shorter and there is not a hydraulic leak, then the pump may be working, but leaking internally. Replace pump. Refer to Hydraulic Pump in the Service/Repair section of this 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 up on the system pressure side of the hydraulic system or the pressure switch circuit is not functioning correctly. Either way the HPU motor cannot run very long before overheating. Please take precaution to avoid overheating when troubleshooting if the motor will not shut off.

Does the unit have adequate system pressure?

No: • Check hydraulic system for bypass/leak. Check HPU main pressure relief, it should be set to 1/2 turn counter-clockwise.

Does the motor shut off when the pressure switch is unplugged?

No: • SSR is defective.

Yes: • Check Pressure Switch.

• Check pressure at pressure switch port with a test gauge.

• Check hydraulic system leakage by inspecting/cleaning PRV and carriage spool valves.

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4 - 2Troubleshooting EP800AD (Acrobat™ HPU)

No Output Pressure

Check electronic valve controller for error codes

• Refer to Electronic Valve Controller section for error codes.

Is HPU motor running at normal cycle times?

No: • Check fuses.

• Make sure high side hydraulics circuit is OK and building pressure. Check pressure at pressure switch port with a 2000 psi test gauge.

Check carriage for free movement

• Turn up all pressure knobs to half or greater range.

• Cycle open/close and pressure selection switch and look for any movement.

No: Check 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: • Check input voltage entering unit.

• Check power switch input voltage CB1.

• Is hour meter hourglass blinking when power is on?

No: Check fuse F2 (110V), fuse F4 (220V).

• Check DC voltage on DC bus: Electrical Schematic (719904) Sheet A

No: Check fuse F5.

Is fuse F1 OK?

No: • Check and replace Fuse F1 (110V).

Is there power present at the motor plug: J1-A : J1-B?

No: • Check SSR for signal & power, check low voltage circuit, check F5.

• Check motor wire, motor, and capacitor deutsch connectors.

Yes: • Replace motor. Refer to HPU Motor in the Service and Repair section of this manual.

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Pressure Selector Switch Not Functioning (selecting between pressure control knobs)

Pressure Control Is Not Stable

Power unit off. Open the lid of the control box. Power the unit on and flip the pressure control switch between each mode, you should see the LED’s on the two din rail relays toggle on and off one at a time.

Exposed electrical components can shock during troubleshooting and testing. Do not touch exposed electrical components with the unit connected to power, the result could be serious injury 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 Electrical Schematic (719904) Sheet A.

• Replace failed relays.

Try cycling the system from low pressure to high pressure a few times. This may clear the debris from the valve.

No: • Air may be trapped in the hoses/system. Check fluid level & bleed per Bleeding Hydraulic System section of this manual.

The high pressure filter may be clogged and bypassing. Check bypass indicator.

No: • Jammed/Silted PRV valve?

Yes: Remove/clean PRV valve. Use a standard parts cleaner.

No: Replace PRV valve.

Yes: • Replace filter. Refer to Change Hydraulic Fluid and Filter section of this manual.

¡ATENCIÓN!

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Open/Close Switch Not Functioning

Main Circuit Breaker Trips

Check power to Open/Close solenoids per switch position. This can be done with a volt meter at the plug that supplies the solenoids power, and should read 24V when switch is in corresponding Open/Close position.

No: • Check open/close switch and wiring per Electrical Schematic (719904) Sheet B.

If the main breaker trips let the unit cool for 3 minutes and try to reset. Does it trip after reset?

Yes: • If the 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 resistance is less, this indicates a shorted fault. If the resistance is

more, this indicates an open fault and the solenoid should be replaced. Refer to Open/Close Solenoid section for more information

Inspect/Check all fuses. • If all fuses check out properly this indicates a fault in either the EMI

filter, main breaker, or the wiring between the main breaker and fuses

Check solenoid retention nut for proper torque.

No: • Loosen nut and re-torque to correct value of 4 - 5 ft-lbs (5.4 - 6.8 Nm).

Yes: • Replace the cartridge valve.

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Fuse F5 Blown

Fuse F1/F3 Blown

Fuse F2/F4 Blown

A fault on the 24v system exists.

• Visually check wiring for damage.

Unplug the motor connector from the system. Does fuse blow?

No: • There may be a problem with the capacitor. Test capacitor independently per HPU Motor and Capacitor section of this manual. If the capacitor is good, then there is a problem with 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 likely a problem with the power supply.

• Replace power supply

Put carriage Open/Close switch in the center position. Does fuse blow?

No: • There is a problem with the Open/Close solenoids or wiring, check wiring, check solenoids.

Yes: • There is a problem with the electronic valve controller and/or PRV solenoid.

• Check the valve controller for error codes.

• Check the wiring to the valve controller and to the PPV solenoid.

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Oil Foams

Heater Receptacle Not Functioning Properly

Quick Disconnects Leaking

Is the hydraulic fluid level low?

Yes: • Add hydraulic fluid. Refer to the Hydraulic Fluid section of this manual for fluid recommendations.

No: • There may be water in the hydraulic fluid, check and replace. Refer to section Changing Hydraulic Fluid.

On newer models of the HPU equipped with receptacles the heater receptacle is controlled in a logical manner as explained in section Electrical Receptacles.

First check the signal 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.

Yes: • The SSR is damaged and needs replaced.

No: • Check the SSR wiring harness and 4 pin connector per the wiring diagram. Verify that the 24V signals from the Pressure Switch and Current Switch are present and behaving correctly.

Were the QD connectors properly clean before connection?

No: • Clean them properly with a spray lubricant such as WD40®, reconnect/disconnect/clean a few times.

Have the QD connectors been connected/disconnected under pressure?

Yes: • The QD seals are not meant to connect/disconnect under pressure, they may be damaged and need replaced.

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5 - 1 Assembly/DisassemblyEP800AD (Acrobat™ HPU)

ASSEMBLY/DISASSEMBLY

OverviewThe EP800AD (Acrobat HPU) frame consists of two molded end plates and a cover assembly, which is held together via tie rods and two frame rails. Mounting plates secure the internal components of the HPU to the external frame. The unitized design reduces weight and provides great structural strength.

End PlatesREMOVAL

1. Remove the handle tube.

2. Remove the two acorn nuts that attach the end plate to the tie rods.

3. Remove the two bolts that attach the end plate to the frame rails.

4. Separate end plate from frame rails and tie rods.

5. Tie rods should come free once both end plates are removed.

INSTALLATION1. 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 frame rails. Apply medium strength thread locking compound. Tighten bolts to 7 ft-lbs (9.5 Nm) torque.

4. Position tie rods into right end plate.

5. Position right end plate at frame rails and cover assembly.

6. Install bolts attaching right end plate to frame rails. Apply medium strength thread locking compound. Tighten bolts to 7 ft-lbs (9.5 Nm) torque.

7. Install acorn nuts attaching tie rods to left and right end plates. Apply medium strength thread locking compound. Tighten bolts to 7 ft-lbs (9.5 Nm) torque.

8. Install the handle tube. Apply medium strength thread locking compound. Tighten bolts to 7 ft-lbs (9.5 Nm) torque.

End Plates

Frame Rails

Cover Assembly

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5 - 2Assembly/Disassembly EP800AD (Acrobat™ HPU)

Cover AssemblyIMPORTANT: The HPU can be run with the cover assembly positioned as shown for troubleshooting.

REMOVAL1. Disconnect all wires connecting the cover assembly to the power pack assembly.

2. Lift and rotate the cover assembly from power pack assembly and rest the cover assembly on its side with the hydraulic filter assembly down.

INSTALLATION1. Connect all wires from the cover assembly to the power pack assembly. Reference electrical section.

2. Rotate and position the cover assembly on the power pack assembly.

3. Install end plates to secure cover assembly in place. Reference end plate installation section.

Cover Assembly

Power Pack Assembly

Hydraulic Filter Assembly

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Power Pack AssemblyREMOVAL

1. Disconnect any hydraulic hoses that attach power pack assembly to the frame of the HPU and the cover assembly. Reference hydraulic section.

2. Remove bolts that attach the power pack assembly to the HPU mounting plate.

3. Separate power pack assembly from HPU mounting plate.

INSTALLATION1. Position power pack assembly on the HPU mounting plate

2. Install bolts attaching power pack assembly to the HPU mounting plate. Apply medium strength thread locking compound. Tighten bolts to 30 ft-lbs (40.7 Nm) torque.

3. Attach hydraulic hoses that were disconnected during disassembly. Reference hydraulic section.

Power Pack Assembly

HPU Mounting Plate

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5 - 4Assembly/Disassembly EP800AD (Acrobat™ HPU)

Mounting PlatesREMOVAL

1. Remove rivets that attach each mounting plate to the frame rails. A 3/16" drill bit may be used to remove rivets.

2. Separate mounting plates from frame rails.

INSTALLATION1. Position mounting plates at frame rails.

2. Install rivets attaching mounting plates to frame rails. A rivet gun with attachments for 3/16" rivets should be used.

Frame Rails

Tank Skid Plate

HPU Mounting Plate

Cord and Hose Mounting Plate

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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 Assembly Bolt 30 ft-lb (40.7 Nm)

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6 - 1Electrical EP800AD (Acrobat™ HPU)

ELECTRICAL

OverviewThis section covers the functions of the different electrical components used as well as the theory of operation for the electrical portion of the EP800AD (Acrobat HPU). Repair and servicing information is included for any serviceable components. Electrical schematics are included for the 120V and 240V models of the HPU. For EP800ADs (Acrobat HPUs) with the previous revision hydraulic manifold, refer to the section Previous Revision for service information particular to that model of the HPU.

Components and FunctionsHour Meter

Powered by a Lithium battery. Display is always “ON”, allowing for visualization of machine run time even when power is off.

Hour Meter will display a flashing hourglass when the machine power switch is on the ON position and internal 24VDC power is available to close the motor relay (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 psi). When system pressure reaches 1350psi (+/- 10 psi), it opens motor relay (K1) and stops the motor.

Pressure Transducer Senses output pressure and feeds it to the electronic valve controller to ensure

pressure matches requested pressure set by the user.

This transducer is fed 24VDC and uses a 4mA – 20mA signal through the electrical box and to the valve controller. This signal is used by the valve controller to ensure accurate control of HPU output pressure.

Close / Open Solenoids These solenoids are energized by 24VDC supplied directly from the electrical box.

Replace only using authorized McElroy parts.

Proportional Pressure Reducing Valve (PRV) This valve uses 24 VDC and a pulsed width modulated signal to control carriage

pressure to the pressure set by the user.

Valve resistance is 20.9 ohm when powered off.

When not powered, the valve is closed and will produce 0 pressure.

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6 - 2 ElectricalEP800AD (Acrobat™ HPU)

Electronic Valve Controller (EVC) The valve controller is powered by 24VDC.

The unit is programmed from the factory with all settings required to run the machine.

The valve controller caps the maximum pressure around 800 psi.

It reads requested user pressure and pressure transducer signal to output a modulated signal to the Proportional Pressure Reducing Valve which regulates HPU output hydraulic pressure.

The valve controller uses LED lights to communicate status of the controller. During normal operation, the following lights should be visible

During a 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+ psiModule Status Green - On Steady Green - On Steady

Comm Status Green - On Steady Green - On Steady

Prop. O/P 1 ON Green - On Steady Green - On Steady

Prop. O/P 2 ON Off Off

Pulse I/P Active Flash On Pressure Selector Operation Yellow - On Constant

Digi. I/P 1 Active Yellow - On Steady Yellow - On Steady

Digi. I/P 2 Active Off Off

Module Status LEDGreen Steady Normal Operation

RED 1 pulse PRV short detected

GREEN 1 pulse PRV Valve open detected

RED 3 pulses Input error detected, Pressure Feedback error, reference voltage error,

GREEN 3 pulses Power Supply error

ORANGE 1 pulse State error

Communication Status LEDGREEN Steady Normal operation

ORANGE 1 pulse State error

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Capacitor

Integral to the function of the motor.

Motor

Used to drive the hydraulic pump.

Motor should always be treated as energized unless unit is disconnected from supply power. Shock hazard could occur serious injury or death.

Carriage Switch – S2

This switch is used to send 24VDC to either the open or close calve solenoids.

In the Neutral Position, the carriage switch does not provide 24VDC to either solenoid.

This switch features a sealed washer to prevent water ingress.

Pressure Selector Switch – S1

This switch is used to select the input potentiometer 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 Pressure Knob – R1Heating Pressure Knob – R2Fusing Pressure Knob – R3

These three knobs are mounted to three-turn input potentiometers, used to regulate output pressure of the HPU.

They are outfitted with a seal nut to prevent water ingress.

ON/OFF Switch – CB1 This part provides power-on indication, circuit protection (10A for 120VAC units / 5A

for 220 VAC units) and enables the HPU.

The ON/OFF switch has an external seal. Failure of this seal will allow water ingress.

The ON/OFF switch provides line-to-neutral for 120VAC and line-to-line isolation for 220VAC circuits. Ground circuit is maintained.

¡ATENCIÓN!

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Motor Fuses – F1, F3

F1 fuse is used to provide protection to the motor for HPUs meant for 120 VAC supply power.

F1 and F3 are used to provide protection to the motor for HPUs meant for 220VAC supply power.

User needs to ensure that fuse holder is screwed hand tight into holder’s body to ensure proper electrical contact and water tightness are achieved.

Power Supply Fuses – F2, F4

F2 fuse is used to provide protection to the power supply for HPUs meant for 120VAC supply power.

F2 and F4 fuses are used to provide protection to the power supply in HPUs meant for 220VAC supply power.

User needs to ensure that holder is screwed hand tight 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 need to be hand tight for proper sealing.

The ventilation plugs prevent moisture build-up within the unit during quick changes in temperature.

Terminal Board

Terminal Blocks 1, 2 provide AC distribution to the HPU.

Terminal Blocks 3-7 provide DC distribution to the HPU.

Terminal Blocks 8-10 provide signal distribution through the HPU.

Line Filter – LF1

Removes electro-magnetic interference and attenuates ripples in incoming power.

Power Supply – PS1

Power Supply takes 87 – 264 VAC, 47 – 63Hz input power and outputs 24 VDC +/- 1%.

Hazardous voltage, remove power to electrical box. Shock could occur causing serious injury or death.

DC Power Fuse – F5

ATC style 3A fuse to protect DC bus.

¡ATENCIÓN!

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Relays

Motor Relay (SSR) – K1 – Receives a 24 VDC signal that enables the passage of power to the motor.

Hydraulic Valve Controller – K2 – A low power 24VDC relay that routes the proper pressure command signal to the electronic valve controller.

Hydraulic Valve Controller – K3 – A low power 24VDC relay that routes the proper pressure command signal to the electronic valve controller.

Electrical Receptacles

The HPU uses current sensing and logic to actively control the power to the heater receptacle. If the facer receptacle current sensor senses that the facer is on or if the HPU motor is running the heater receptacle will be disabled. Otherwise the heater receptacle will be enabled.

Theory of Operation (Electrical)With the unit plugged-in, the following is the manner of operation for the machine.

Power Section

• The user 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 draw exceeds the rating of the breaker within the ON/OFF switch, the switch will trip and disable the machine. To troubleshoot the machine, prior to restoring power after a breaker trip. A manual reset of the ON/OFF switch is needed to restore power.

• The line filter conditions the power traveling through the ON/OFF switch.

• Power goes from the line filter to terminal blocks 1 and 2 for distribution to the motor and Power Supply.

• Power for the power supply goes through the fuses to the power supply. The power supply converts the AC voltage to a 24VDC voltage.

• DC voltage travels through an ATC style 3A fuse and is distributed through Terminals 3 – 7 to the different DC components of the HPU unit.

• The hour meter begins to record machine run time when it senses 24VDC at Terminals 3 – 7 (indicated by blinking hourglass). Hours are displayed even when the power is off.

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• The main pressure switch receives 24 VDC from the power supply which enables this sensor. Upon power-up, the sensor detects HPU system pressure. This is the built or residual pressure between the accumulator and the PRV valve. If detected system pressure is below 850 psi, the main pressure switch will send 24 VDC through pin 3 to the (+) side of motor relay (K1). This enables the motor which will start turning.

The main pressure switch will maintain 24VDC through pin 3 until it senses that the system pressure has reached 1350psi. When system pressure reaches 1350 psi, the main pressure switch removes 24VDC from pin 3 which disables the motor relay and stops the motor.

• With motor relay (K1) enabled, the solid state relay will enable power to the motor. Power for the motor goes through the fuses and through motor relay (K1). This power also charges the capacitor which is used as an aid to allow the motor to rotate upon start-up.

• The hydraulic pump will build-up pressure from 0 psi to 1350 psi in approximately 13 to 17 seconds upon start-up; the hydraulic pump will turn on every three minutes approximately for 5 to 8 seconds to maintain 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 placed on either the open or the close solenoid.

• The electronic valve controller is wired through the terminal block to the PRV. The valve controller modulates the signal to the PRV solenoid to either increase or decrease output pressure as demanded by the user.

• To receive user input, the valve controller relies on a reference signal placed through one of three potentiometers.

• The reference signal is 5 VDC and is provided from the “RefOut” pin of the controller. It is placed across all 3 potentiometer’s extremities.

• The pressure selector switch determines which potentiometer output voltage gets routed back to the “ANI2” pin of the controller via activating relays K2 and K3. The relays serve as isolation between the 5V reference signal and the 24V control signal.

• The Feedback Pressure Transducer checks the output pressure to the carriage and relays this sensed pressure to the valve controller in the form of a 4mA – 20mA signal.

• The reference signal received by the valve controller is compared to the pressure sensed by the feedback pressure transducer. From this comparison, the valve controller determines the error and makes adjustments to the PRV output signal as needed.

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Service and RepairProportional Pressure Reducing Valve (PRV) Solenoid

The PRV solenoid is used to magnetically control the spool of the PRV valve. It is driven by a digitally controlled PWM power driver inside the valve controller and is otherwise non-serviceable.

NOTICE: The valve controller is programmed from the factory and the software and hardware are not field serviceable.

The valve controller can usually detect a fault in the solenoid and will blink its module status light red (fast, 0.25s on, 0.25s off)

The resistance of the solenoid may be checked and should be 18 (± 5) Ohms. If the resistance is less this indicates 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 24V from the Open/Close switch.

The resistance of the solenoid may be checked and should be 34 (± 5) Ohms. If the resistance is less this indicates a shorted fault, if the resistance is more this indicates an open fault.

If the resistance is OK and voltage is present at the solenoid’s wire plug the solenoid may be checked by removing the solenoid from the valve stem and placing a screwdriver or metal object through the middle. If the solenoid is on you should feel a magnetic field holding the screwdriver in place, this indicates that the solenoid good and attempting to actuate the spool.

Ω18.0

Ω34.0

Open/Close Solenoids

Proportional Pressure Reducing Valve Solenoid

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24V Power Supply

The power supply is open frame so use caution when the electrical box is open and the unit is powered on.

Exposed electrical components can shock during troubleshooting and testing. Do not touch exposed electrical components with the unit connected to power, the result could be serious injury or death.


NOTICE: The electronic valve controller is factory programmed and non-serviceable.

There are two LEDs on the unit that can show the status of the controller and can help diagnose issues.

If cycling the power does not clear a reported problem or the reported problem does not pertain to a feature being used on this HPU then the controller will need to be 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 detected

GREEN 2 pulses . . . . . . . . . . . . . . . . . . .Output B (not used) open detected

RED 3 pulses . . . . . . . . . . . . . . . . . . . . . .Input error detected, reference voltage error

GREEN 3 pulses . . . . . . . . . . . . . . . . . . .Power supply error

GREEN 4 pulses . . . . . . . . . . . . . . . . . . .Reverse retry fail error

RED 4 pulses . . . . . . . . . . . . . . . . . . . . . .Pot not centered at reset error

ORANGE 1 pulses . . . . . . . . . . . . . . . . .State error

Communication Status LED:

GREEN steady . . . . . . . . . . . . . . . . . . . .Normal operation

GREEN with ORANGE pulses . . . . . . . .Serial port (GUI) traffic

ORANGE/ RED pulsing. . . . . . . . . . . . .Receiving SAE J1939 traffic

RED 1 pulses . . . . . . . . . . . . . . . . . . . . . .SAE J1939 set point message timeout

RED 2 pulses . . . . . . . . . . . . . . . . . . . . . .SAE J1939 engine rpm message timeout

RED 3 pulses . . . . . . . . . . . . . . . . . . . . . .Pot not centered at reset error

ORANGE 1 pulses . . . . . . . . . . . . . . . . .State error

Electronic ValveController

- Prop. O/P 1 ON

- Prop. O/P 2 ON

- Pulse I/P Active

- Digi. I/P 1 Active

- Digi. I/P 2 Active

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¡ATENCIÓN!

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HPU Motor and CapacitorThe motor is an AC induction motor and has no serviceable parts. A single capacitor is used to start/run the motor and it is mounted externally immediately beside the electrical enclosure toward the user.

The capacitor can be checked with a standard capacitance meter. It may be replaced independently of the motor in the event that it fails and the motor is not damaged.

The motor may also be replaced independently of the HPU hydraulics if necessary without affecting the hydraulic components or draining the fluid.

Remove Motor:

1) Remove the 4 Motor Bolts using a 1/4" socket.

2) Slide the Motor from the hydraulic reservoir.

3) Remove the Coupler and Bearing from 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 Motor onto the Adapter Plate. Ensure the slotted end of the Coupler fits into the Pump.

6) Install the 4 Motor Bolts. Torque the bolts to 20-25 ft-lbs (27-34 Nm).

Main Pressure SwitchThe main pressure switch is responsible for cycling the HPU motor to maintain a system pressure range of 830psi to 1350psi. The switch connects 24VDC through internal contacts to the SSR which turns on the HPU motor. The 24V power supply must be operational and all fuses must be intact for the HPU motor to function.

A continuity check can be made across the two wires of the pressure switch with the dump valve open. Continuity should be present.

Pressure Switch Dump Valve

Motor to Pump Coupler

Motor Bearing

Adapter Plate

Motor Bolts

Motor

Capacitor

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Feedback Pressure Transducer

The feedback 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 always be replaced in conjunction with the valve controller.


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Electrical SymbolsCAPACITOR - C1 MECHANICAL RELAY - K2, K3

CIRCUIT BREAKER – ON/OFF SWITCH - CB1 SOLID STATE RELAY - K1

CHASSIS GROUND POWER SUPPLY - PS1

FUSE - F1, F2, F3, F4

LINE FILTER - LF1

CBxXXA

CIRCUIT BREAKER THERMAL

CHASSIS GROUND

Fx

FUSE

XA

LFx

NN’

P’

P

E

LINE FILTER

SOLID STATERELAY

A1+ A2

T1 L1

Kx

PSx

POWER SUPPLY

C1–3 C2–4

C2–2

AC(N) +Vout

-VoutAC(L)C1–1

+

CxCAPACITOR MECHANICAL RELAY

12

14

11A1+

A2

Kx

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Electrical Schematic (719904) Sheet A, Rev A 100-120V, 50/60Hz, 1Ph w/ Outlets

NO

TE: All w

ires are 20 AWG

unless otherw

ise noted. Reference IllustrationsCover Assembly

Control Box

Power Pack Assembly


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Electrical Schematic (719904) Sheet B, Rev A 100-120V, 50/60Hz, 1Ph w/ Outlets

NO

TE: A

ll w

ires

are

20 A

WG

unl

ess

othe

rwise

not

ed.

Reference IllustrationsCover Assembly

Control Box

Power Pack Assembly


Elec

tric

al


Electrical Schematic (721002) Rev A 208-240V, 50/60Hz, 1Ph w/ Outlets

NOTE: All wires are 20 AWG unless otherwise noted.

Denotes wire splice.


Control Box

Power Pack Assembly


Elec

tric

al


Electrical Schematic (721002) Rev A 208-240V, 50/60Hz, 1Ph w/ Outlets

NOTE: All wires are 20 AWG unless otherwise noted.


Control Box

Power Pack Assembly


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7 - 1Hydraulic EP800AD (Acrobat™ HPU)

HYDRAULIC

OverviewThis section covers the functions of the different hydraulic components used as well as the theory of operation for the hydraulic portion of the EP800AD (Acrobat HPU). Repair and servicing information is included for any serviceable components. Hydraulic schematics are included for the HPU. For EP800ADs (Acrobat HPUs) with the previous revision hydraulic manifold, refer to the section Previous Revision for service information particular to that model of the HPU.

Components and Functions (Hydraulic)Hydraulic Power Unit

An electric motor turns a gear pump and is mounted to an adapter plate. The pump is enclosed in a metal reservoir that also attaches to the adapter plate.

Hydraulic Manifold This component houses the dump valve, pressure control valve and directional valve.

Dump valve - 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 Valve - This is a solenoid controlled cartridge valve that maintains a selected pressure to the fusion carriage.

Directional Control Valve - This is a dual solenoid cartridge valve that directs pressurized fluid to open or close the carriage.

Accumulator Stores pressurized hydraulic fluid between 830 and 1350 psi and supplies

pressurized fluid to the pressure control valve. It is charged with 680 psi of dry nitrogen gas.

Pressure Switch Monitors accumulator pressure and sends an electrical signal to the electric motor so

that the pump turns to recharge the accumulator. This switch maintains accumulator pressure between 830 and 1350 psi.

Feedback Pressure Transducer Provides carriage pressure feedback signal to the pressure reducing valve in order to

maintain selected carriage pressure.

Pressure Gauge Shows output pressure to the fusion carriage.

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7 - 2 HydraulicEP800AD (Acrobat™ HPU)

Hydraulic Filter Filters oil from the pump to the accumulator. Removes particles larger than 3 micron in

size.

Theory of Operation (Hydraulic)Hydraulic Power Unit

With the unit plugged-in, the following is the manner of operation for the machine.

• The HPU is powered by a 0.3 HP electric motor that drives a .065 in³/rev (1/2 GPM) hydraulic gear pump.

• The pump supplies pressurized hydraulic fluid through a high pressure 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 pressure independently using electrical rheostats. These pressures can be set to approximately 800 psi.

• The selected pressure is delivered to a solenoid controlled directional valve that in turn delivers flow to open or close the carriage.

• Hydraulic return fluid from the carriage is directed through the manifold to hydraulic reservoir.

• When the system pressure drops below 830 psi the electric motor starts and the pump recharges the accumulator to 1350 psi.

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Service and RepairCheck Hydraulic Fluid

Before connecting to power and with the machine off, open the plug on the end of the reservoir. The fluid level should be up to opening when the HPU is on a level surface. Refer to the Hydraulic Fluids section of this manual 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) Drain the reservoir of all hydraulic fluid using the drain plug at the bottom of the reservoir.

3) Remove the 4 reservoir bolts using a 3/8" wrench. Remove the Reservoir from the Adapter Plate. Inspect o-ring, replace if damaged.

Reservoir Plug

Drain Plug

Reservoir Bolts

Adapter Plate

Reservoir

Reservoir O-ring

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4) Remove the Fluid Pick-up from 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 from cavity in the Adapter Plate.

Pick-up O-ring

Fluid Pick-up

Pump

O-ring

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7) Remove the large return tube with washers and O-ring from the Adapter 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 into the Adapter Plate where the Pump will mount. Install the Hydraulic Pump onto the Adapter Plate.

Pump

O-ring

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3) Install the 4 Hydraulic Pump mounting bolts using a 8mm socket. Torque the mounting bolts to 10-11 ft-lb (13.5-15 Nm)

4) Install a new Pick-up 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 Reservoir Bolts through the Reservoir and into the Adapter Plate. Torque the Reservoir Bolts to 20-25 in-lb (2.3-2.8 Nm)

Pick-up O-ring

Fluid Pick-up

Reservoir Bolts

Adapter Plate

Reservoir

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6) Fill the reservoir with new hydraulic fluid.

Open the plug on the end of the reservoir. The fluid level should be up to opening when the HPU is on a level surface. Refer to the Hydraulic Fluids section of this manual for hydraulic fluid recommendations.

Reservoir Plug

Bleeding Air From EP800AD (Acrobat HPU)

1) Fill hydraulic reservoir according to procedure Check Hydraulic Fluid in this manual.

2) Connect the quick disconnects together at the end of the hoses.

3) Move the 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 directional control (D) to the open position. Allow fluid to circulate for 30 seconds.

6) Shift the carriage directional control (D) to the close position and circulate fluid for 30 seconds.

7) Reduce the fusing pressure completely by turning the knob (B) counter-clockwise. Ensure zero pressure is shown on the carriage pressure gauge (E).

8) Turn the EP800AD (Acrobat HPU) off (C).

9) Refill the hydraulic reservoir. Refer to the Hydraulic Fluid section of this manual for hydraulic fluid recommendations.

FUSES

MOTOR POWERSUPPLY

E

A

D B

C

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Change Hydraulic Fluid and FilterThis HPU is equipped with a 3 micron cartridge filter with a bypass indicator on the top of the unit. If the indicator is activated, the filter needs to be changed otherwise 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 replace with a new filter cartridge. Install the bowl on the filter housing.

The hydraulic fluid should be replaced every year.

Fill the reservoir from a clean container. Refer to the Hydraulic Fluid section of this manual for hydraulic fluid recommendations.

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Hydraulic SymbolsPRESSURE GAUGE QUICK DISCONNECT RELIEF VALVE

PRESSURE TRANSDUCER CHECK VALVE ELECTRIC MOTOR

HYDRAULIC FILTER NEEDLE VALVE HYDRAULIC PUMP

HYDRAULIC TANK PRESSURE SWITCH PRESSURE CONTROL VALVE

HYDRAULIC HOSE HYDRAULIC ACCUMULATOR DIRECTIONAL CONTROL VALVE

M

PRESSURECONTROLSWITCH

PRESSURE

TRANSDUCERPRESSURE NEEDLE

VALVE

VALVE

GAUGEPRESSURE

DIRECTIONALCONTROLVALVE

RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE

HYDRAULICACCUMULATOR

M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


M


PRESSURE


VALVE

VALVE

GAUGEPRESSURE


RELIEFVALVE

HYDRAULICFILTER

CHECKVALVE

HYDRAULICTANK

ELECTRICMOTOR

HYDRAULICPUMP

QUICKDISCONNECT

HYDRAULICHOSE


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M0.4 GPM HPU

PRESSURE

AB

S1

S2

CONTROL

DIRECTIONAL VALVE

G PS SW

ACC

SWITCH

PRESSURE

(830-1350 PSI)

TRANSDUCER

PRESSURE

ACCUMULATOR

BLEED VLV

FILTER

HIGH PRESSURE

(87 PSID BYPASS)

VALVE

RELIEF VALVE

GAUGE

PRESSURE

F1

F0

TR

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5-3

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4640

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Hydraulic Schematic

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Replacement PartsThis section includes a list of replacement parts for the hydraulic system of the EP800AD (Acrobat HPU). The list of parts is correct at the time of printing. To always find the latest parts available for your HPU, go to the McElroy parts finder at www.mcelroy.com

Part Description Part Number Feedback Pressure Transducer MQB00092

Pressure Gauge MEE00073

Pressure Filter Kit MED00097

Pressure Filter Replacement Element MED00099

Accumulator MER00006

Pressure Switch MKP00005

Pressure Control Valve MEG00051

Directional Valve MEF00231

Directional Valve Solenoid MEF00325

120V Hydraulic Power Unit Assembly MEA00163 (Includes Pump, Motor, Reservoir and Manifold)

240V Hydraulic Power Unit Assembly MEA00164 (Includes Pump, Motor, Reservoir and Manifold)

Hydraulic Pump MEA00154

3/8" FSAE Quick Disconnect Coupler MFH00062

3/8" FSAE Quick Disconnect Nipple MFH00063

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Standard Hydraulic Fluids CharacteristicsManufacturer Fluid Name cSt cSt V.I. -20F -10F 0F 10F 30F 50F 70F 90F 110F 130F 150F Range Range 100F 210F °F °C

Mobil DTE 10 Excel 15 15.8 4.1 168 ************************************************** -16 - 113 -27 - 45

DTE 10 Excel 32 32.7 6.6 164 *************************************************** 12 - 154 -11 - 68

DTE 10 Excel 46 45.6 8.5 164 **************************************************** 23-173 -5 - 78

DTE 10 Excel 68 68.4 11.2 156 *************************************************** 37-196 3 - 91

Univis N-32 34.9 6.9 164 *************************************************** 12-150 -11 - 66

Univis N-46 46 8.5 163 *************************************************** 24-166 -4 - 74

Univis N-68 73.8 12.1 160 ************************************************** 39-193 4 - 89

Hydraulic FluidThe use of proper hydraulic fluid is mandatory to achieve maximum performance and machine life. Use a clean, high quality, anti-wear hydraulic fluid with a viscosity index (VI) of 135 minimum. It should have a maximum viscosity of 500 cSt (2000 SSU) at startup (ambient temperature) and a minimum viscosity of 13 cSt (65 SSU) at the maximum fluid temperature (generally 80°F above ambient). Using hydraulic fluids that do not meet these criteria may cause poor operation and/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 ambient temperature depending on the pressure setting, age of the pump, wind, etc. Mobil Univis N46 hydraulic fluid is currently installed at our factory. The advantage of this fluid is a wider temperature range, however, this fluid should not be used for continuous operation below 24°F.

On earlier versions of the EP800AD (Acrobat HPU), a Synthetic 46 Hydraulic Fluid was used and should continue to be used on those HPUs.

NOTE: This chart is based on pump manufacturer recommendations of 13 to 500 cSt.

NOTE: Temperatures shown are fluid temperatures. – NOT ambient temperatures.

Hydraulic Power Unit Lubricant Capacity Specification/Notes

EP800AD (Acrobat HPU) with 3 micron filter

Mobil Univis N46 hydraulic fluid

0.375 gal (1.41 liters) Installed at factory. Use chart below to select a different fluid.

EP800AD (Acrobat HPU) with 10 micron filter incorporated in hydraulic manifold

Synthetic 46 hydraulic fluid 0.375 gal (1.41 liters) HPUs with manifold incorporated cartridge filter.

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8 - 1Previous Revisions EP800AD (Acrobat™ HPU)

PREVIOUS REVISIONS

OverviewPrevious versions of the EP800AD (Acrobat HPU) has some components that differ from the current model of the machine. Those components are identified here with information specific to those components. The two revisions outlined here are Revision 1 and Revision 2.

Revision 1Revision 1 of the HPU has a different cover assembly which has the hour meter and DataLogger port on the top of the cover assembly. This revision has a hydraulic manifold block with a 10 micron filter. There is also a bleeder hose that is under the cover assembly. The hydraulic hoses to the carriage are routed from the side of the HPU.

Hour Meter Hydraulic Pressure Gauge

DataLogger Port


Cover Assembly

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8 - 2 Previous RevisionsEP800AD (Acrobat™ 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)


Power Pack Assembly (Revision 1 and 2)

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Bleed Hose

Bleed Hose Plug

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 CNTRL

PS SWACC

G

DIR VLV

B

Manifold Block (Revision 1 and 2)

Bleed Hose

DataLogger® Port

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Revision 2Revision 2 of the HPU has the same components as the Revision 1. This revision has an additional 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 Meter

Electrical Power Receptacles

Filter Bypass Indicator

Facer Receptacle Heater Receptacle

Cover Assembly (Revision 1 and 2)


Control Box

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Electrical Schematic Revision 1 and 2 (719902) Sheet A, Rev D 100-120V, 50/60Hz, 1Ph, No Outlets

NO

TE: All w

ires are 20 AWG

unless otherw

ise noted.


Control Box

Power Pack Assembly


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ious

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Electrical Schematic Revision 1 and 2 (719902) Sheet B, Rev D 100-120V, 50/60Hz, 1Ph, No Outlets

NO

TE: A

ll w

ires

are

20 A

WG

unl

ess

othe

rwise

not

ed.


Control Box

Power Pack Assembly


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ious

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isio

ns


Hydraulic Schematic (Revision 1 and 2)

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Change Hydraulic Fluid and Filter (Revision 1 and 2)

The Revision 1 and 2 HPUs are equipped with a 10 micron cartridge filter (A) behind the plug on the manifold block.

Revision 2 HPU models include a 3 micron pressure filter (B) located below the accumulator of the HPU with a filter bypass indicator. If the indicator is activated, the filter needs to be changed otherwise the filter should be replaced 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. Install the plug. Tighten plug to 50 ft-lb.

To change the 3 micron filter: Use a wrench to remove the bowl from the filter housing. Remove the old filter cartridge and replace with a new filter cartridge. Install the bowl on the filter housing.

The hydraulic fluid should be replaced every year.

Fill the reservoir from a clean container. Refer to the Hydraulic Fluids section of this manual for hydraulic fluid recommendations.

AB

Service and Repair (Revision 1 and 2)

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FUSES

MOTOR POWERSUPPLY

G

E

F

A

D

C

B

Bleeding Air From EP800AD (Acrobat HPU) (Revision 1 and 2)

1) Fill hydraulic reservoir according to procedure Check Hydraulic Fluid in this manual.

2) Connect the quick disconnects together at the end of the hoses.

3) Move the pressure selector control (A) to fusing pressure.

4) Set the fusing pressure knob (B) to max setting by turning the knob clockwise.

5) Turn the EP800AD (Acrobat HPU) on (C) and move the carriage directional control (D) to the open position. Allow fluid to circulate for 30 seconds.

6) Shift the carriage directional control (D) to the close position and circulate fluid for 30 seconds.

7) Reduce the fusing pressure completely by turning the knob (B) counter-clockwise. Ensure zero 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 the quick disconnects at the end of the hoses.

11) Turn the EP800AD (Acrobat HPU) on (C).

12) Move the carriage directional control (D) to the close position and set the fusing pressure between 30 and 40 PSI.

13) Loosen the plug on the end of the bleeder hose (E) to allow fluid to trickle out. Allow the fluid to trickle out until all signs of air are removed. Tighten the plug on the bleeder hose (E).

13) Attach a separate bleeder hose to the DataLogger Port (G) on the HPU. Allow fluid to trickle out until all signs of air are removed. Remove the bleeder hose from the DataLogger Port (G).

14) Increase/decrease pressure with the fusing pressure knob (B) from 0-800 PSI for 10 cycles.

15) Turn the HPU off (C) and refill the hydraulic reservoir according to procedure Check Hydraulic Fluid in this manual.

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Replacement PartsThis section includes a list of replacement parts for the hydraulic system of the EP800AD (Acrobat HPU). The list of parts is correct at the time of printing. To always find the latest parts available for your HPU, go to the McElroy parts finder at www.mcelroy.com

Part Description Part Number Feedback Pressure Transducer MQB00092

Pressure Gauge MEE00067

Pressure Filter Kit MED00097

Pressure Filter Replacement Element MED00099

Accumulator MER00006

Pressure Switch MKP00005

10 Micron Return Replacement Filter MEA00151

Pressure Control Valve MEG00051

Directional Valve MEF00231

Directional Valve Solenoid MEF00325

120V Hydraulic Power Unit MEA00157 (Includes Pump, Motor and Reservoir)

3/8” FSAE Quick Disconnect Coupler MFH00062

3/8” FSAE Quick Disconnect Nipple MFH00063

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9 - 1Post Service Function Checks EP800AD (Acrobat™ HPU)

POST SERVICE FUNCTION CHECKS

Post Service Function Checks1) Plug in HPU.

2) Ensure dump valve is closed by turning the valve knob fully clockwise until hand tight.

3) Turn on machine by pressing ON-OFF switch. ON-OFF switch shall light up.

• If ON-OFF switch does not light up, ensure black wire is connected to Line side of ON-OFF switch. The ON-OFF switch has the word “LINE” engraved next to the connection point in the part.

4) The motor will come on immediately after turning on the machine (if the unit has been off for a long period of time). The motor should run for 5-10 seconds and no longer than 15 seconds.

If the motor doesn’t come on:

• Lack of 24 VDC, see step 5.

• Main Pressure Switch Cable, is not wired correctly at connector.

• Main Pressure Switch Cable, 24VDC signal is not wired to K1 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 making pressure. Refer to HPU Motor Does Not Shut Off in the Troubleshooting section.

• A motor that pulses on and off quickly may indicate a hydraulic/accumulator issue.

5) Check the hour meter for a blinking hourglass symbol. This indicates that the hour meter is receiving 24 VDC.

Note:

• Hour meter is NOT polarity sensitive.

6) Plug the facer appropriate for the EP800AD (Acrobat HPU) into the Facer accessory receptacle.

7) Plug the heater appropriate for the EP800AD (Acrobat HPU) into the Heater accessory receptacle. Verify that the heater receptacle is enabled.

Troubleshooting:

• The heater receptacle is controlled through the SSR wiring harness.

• Check that the SSR wiring harness is hooked up properly per Electrical Schematic 719904 Sheet B.

• Check wiring of 120VAC input and DC output of Power Supply. Wiring should match Power Supply schematic on Electrical Schematic.

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9 - 2 Post Service Function ChecksEP800AD (Acrobat™ HPU)

8) With the heater being powered by the heater accessory receptacle, turn on the facer, the heater should go off. Turn the facer off and the heater should come back on. This tests if the facer current sensing switch is working correctly.

Note:

• If the HPU motor comes on to recharge the accumulator the heater will also go off, this is intentional and will be tested in the next step.

Troubleshooting:

• The heater receptacle is controlled through the SSR wiring harness


9) Let the heater remain on until the HPU motor cycles on. While the HPU motor is on the heater should be off. This tests if the heater/HPU receptacle logic is working correctly.

Troubleshooting:

• The heater receptacle is controlled through the SSR wiring harness


10) Place the Carriage Switch in the Close position.

11) Select the Facing position of the Pressure Selector Switch.

12) Move the corresponding potentiometer clockwise, the pressure should increase on the gauge. Move the corresponding potentiometer counterclockwise, the pressure should decrease on the gauge. Ensure the pressure range is freely adjustable from 70 to 810psi. Leave the pressure set at 0 psi.

13) Perform steps 11 – 13 with the Heating and Fusing positions of the Pressure Selector Switch.

Troubleshooting:

• If system is unable to regulate pressure, check for air in system.

• Check potentiometer cabling and all connections to Relays K2 and K3, refer to Electrical Schematic 719904.

14) Verify pressure is set to 0 psi.

15) Toggle the Carriage Switch a few times to ensure the carriage hoses do not contain any residual pressure.

16) Connect a carriage to the EP800AD (Acrobat HPU) unit.

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vice

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9 - 3Post Service Function Checks EP800AD (Acrobat™ HPU)

18) Set the HPUs pressure to 300psi.

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 Schematic (719904).

• Check that open/close solenoids are plugged into correct connectors

20) Turn off EP800AD (Acrobat HPU).

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10 - 1 NotesEP800AD (Acrobat™ HPU)

NOTESNotes

ep800ad (acrobat™ hydraulic power unit) service manualjul 07, 2016 · using the service manual...

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