Summary of Contents for McElroy Acrobat EP800AD
- Page 1 EP800AD (Acrobat™ Hydraulic Power Unit) SERVICE MANUAL Manual: 718601 Rev D 11/19 EP800AD (Acrobat™ HPU)
- Page 3 McElroy Technical Services at 918-831- 9224 or techsupport@mcelroy.com. Designations used by component suppliers to distinguish their products which appear in this manual are the property of the Service training is available from McElroy University at www.
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Page 4: Table Of Contents
TABLE OF CONTENTS SAFETY AND GENERAL INFORMATION Using the Service Manual ..........1 - 1 Warranty . - Page 5 Heater Receptacle Not Functioning Properly ........4 - 6 Oil Foams .
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Page 6: Safety And General Information
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. -
Page 7: Read And Understand
Do Not Modify Machine Make no modifications to your equipment unless specifically recommended or requested by McElroy. General Safety Safety is important. Report anything unusual that you notice during set up or operation. -
Page 8: Electrical Safety
Electrical Safety Always 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 ¡ATENCIÓN! chances of an electric shock. Frequently inspect electrical cords and unit for damage. Have damaged components replaced and service performed by a qualified electrician. -
Page 9: Replacement Parts
Replacement Parts Refer 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 Designators Reference Designators are assigned to components shown on the schematics and other reference diagrams. -
Page 10: Fastener Identification
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 Safety and General Information 1 - 5... -
Page 11: Machine Specifications
MACHINE SPECIFICATIONS Machine Orientation Left, right, front, and rear of the machine are noted from the perspective of an operator standing in front of the electrical box. REAR LEFT RIGHT FRONT EP800AD (Acrobat™ HPU) Nameplate Location Every unit has a name plate that includes the machine’s model number, serial number, and power requirements. -
Page 12: Machine Specification
Machine Specification Machine Length: 22.1" (562 mm) Machine Width: 12.25" (31 1 mm) Machine Height: 19" (482.5 mm) Machine Weights: 56 lbs (25.4 Kg) 22.1" 12.25" 22.1" 12.25" (562mm) (562mm) (311mm) (31 1mm) 19" 19" (482.5mm) (482.5mm) Hydraulic Specifications Reservoir Filling Capacity: 0.375 gal (1.41 liters) Hydraulic Pressure: 800 psi max. - Page 13 This page was intentionally left blank EP800AD (Acrobat™ HPU) 2 - 3 Machine Specifications...
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Page 14: Component Locations
Complete HPU Hydraulic Control Box Pressure Gauge Bypass Filter Voltage Label Indicator Machine and Heater Amperage Label McElroy High Voltage Branding Label Label Cover Assembly Handle Tube End Plate End Plate Electrical Receptacle Label Hour Meter McElroy... -
Page 15: Cover Assembly
Cover Assembly Cover Assembly Feedback Pressure Transducer Hydraulic Fluid Control Box Electronic Valve Filter Controller Cover Assembly (Control Box Cover Removed) Capacitor Control Box EP800AD (Acrobat™ HPU) 3 - 2 Component Locations... -
Page 16: Control Box
Control Box On/Off Switch Facing Pressure Knob Motor Fuse Heating Pressure Knob Power Supply Fuse Motor Fuse Pressure Selector Switch Power Supply Fuse Fusing Pressure Knob Carriage Switch Terminal Boards DC Power Fuse Line Filter Pressure Selection Relay Motor Relay (SSR) Pressure Selection Relay... -
Page 17: Power Pack Assembly
Power Pack Assembly Hydraulic Breather Cap Accumulator Hydraulic Check/Fill Plug Close Valve Solenoid Hydraulic Quick Disconnects Pressure Relief Proportional Pressure Reducing Open Valve Valve (PRV) Solenoid Hydraulic Manifold Block Dump Valve Pressure Switch DataLogger ® Hydraulic Port Drain Plug EP800AD (Acrobat™ HPU) 3 - 4 Component Locations... -
Page 18: Hydraulic Manifold Block
Hydraulic Manifold Block Carriage Close Port Carriage Open Port Filter to Manifold Port Manifold to Filter Port Directional DIR VLV Valve Port DMP VLV Dump Valve Port Accumulator Port Pressure Switch Port PS SW Pressure Control Port PRESS CNTRL DataLogger ®... -
Page 19: Troubleshooting
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. Does the motor shut off when the pressure switch is unplugged? • SSR is defective. -
Page 20: Hpu Motor Does Not Run
HPU Motor Does Not Run Is main power switch light on when On/Off switch is on? • Check input voltage entering unit. • Check power switch input voltage CB1. • Is hour meter hourglass blinking when power is on? Check fuse F2 (1 10V), fuse F4 (220V). •... -
Page 21: Pressure Control Is Not Stable
Pressure Control Is Not Stable Try cycling the system from low pressure to high pressure a few times. This may clear the debris from the valve. • Air may be trapped in the hoses/system. Check fluid level & bleed per Bleeding Hydraulic System section of this manual. -
Page 22: Open/Close Switch Not Functioning
Open/Close Switch Not Functioning Check power to solenoids per switch position. This can Open/Close 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. • Check open/close switch and wiring per Electrical Schematic (719904) Sheet Check solenoid resistance, solenoid should read around 34 (+/- 5) -
Page 23: Fuse F5 Blown
Fuse F5 Blown A fault on the 24v system exists. • Visually check wiring for damage. Put carriage Open/Close switch in the center position. Does fuse blow? • There is a problem with the Open/Close solenoids or wiring, check wiring, check solenoids. Yes: •... -
Page 24: Heater Receptacle Not Functioning Properly
Heater Receptacle Not Functioning Properly 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 then the control side of the circuit is... -
Page 25: Assembly/Disassembly
ASSEMBLY/DISASSEMBLY Overview The 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. -
Page 26: Cover Assembly
Cover Assembly IMPORTANT: The HPU can be run with the cover assembly positioned as shown for troubleshooting. REMOVAL Disconnect all wires connecting the cover assembly to the power pack assembly. Lift and rotate the cover assembly from power pack assembly and rest the cover assembly on its side with the hydraulic filter assembly down. -
Page 27: Power Pack Assembly
Power Pack Assembly REMOVAL Disconnect any hydraulic hoses that attach power pack assembly to the frame of the HPU and the cover assembly. Reference hydraulic section. Remove bolts that attach the power pack assembly to the HPU mounting plate. Separate power pack assembly from HPU mounting plate. INSTALLATION Position power pack assembly on the HPU mounting plate Install bolts attaching power pack assembly to the HPU mounting plate. -
Page 28: Mounting Plates
Mounting Plates REMOVAL Remove rivets that attach each mounting plate to the frame rails. A 3/16" drill bit may be used to remove rivets. Separate mounting plates from frame rails. INSTALLATION Position mounting plates at frame rails. Install rivets attaching mounting plates to frame rails. A rivet gun with attachments for 3/16" rivets should be used. -
Page 29: Torque Specifications
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) EP800AD (Acrobat™ HPU) 5 - 5 Assembly/Disassembly... -
Page 30: Electrical
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. - Page 31 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.
- Page 32 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. ¡ATENCIÓN! Carriage Switch – S2 This switch is used to send 24VDC to either the open or close calve solenoids.
- Page 33 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.
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Page 34: Theory Of Operation (Electrical)
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 –... - Page 35 • 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).
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Page 36: Service And Repair
Service and Repair Proportional 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. - Page 37 - Digi. I/P 1 Active - Digi. I/P 2 Active Electronic Valve www.mcelroy.com Controller Valve Controller Module Status LED: GREEN steady ....Normal operation RED 1 pulse .
- Page 38 HPU Motor and Capacitor The 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.
- Page 39 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.
- Page 40 This page was intentionally left blank Electrical 6 - 11 EP800AD (Acrobat™ HPU)
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Page 41: Electrical Symbols
Electrical Symbols CAPACITOR - C1 MECHANICAL RELAY - K2, K3 A1 + CAPACITOR MECHANICAL RELAY CIRCUIT BREAKER – ON/OFF SWITCH - CB1 SOLID STATE RELAY - K1 SOLID STATE RELAY CIRCUIT BREAKER THERMAL CHASSIS GROUND POWER SUPPLY - PS1 C1–3 C2–4 AC(N) +Vout... -
Page 42: Electrical Schematic (719904) Sheet A, Rev A 100-120V, 50/60Hz, 1Ph W/ Outlets
Electrical Schematic (719904) Sheet A, Rev A 100-120V, 50/60Hz, 1Ph w/ Outlets Reference Illustrations Cover Assembly Control Box Power Pack Assembly Hydraulic Manifold Block Electrical 6 - 13 EP800AD (Acrobat™ HPU) -
Page 43: Electrical Schematic (719904) Sheet B, Rev A 100-120V, 50/60Hz, 1Ph W/ Outlets
Electrical Schematic (719904) Sheet B, Rev A 100-120V, 50/60Hz, 1Ph w/ Outlets Reference Illustrations Cover Assembly Control Box Power Pack Assembly Hydraulic Manifold Block EP800AD (Acrobat™ HPU) 6 - 14 Electrical... -
Page 44: Electrical Schematic (721002) Rev A 208-240V, 50/60Hz, 1Ph W/ Outlets
Electrical Schematic (721002) Rev A NOTE: All wires are 20 AWG unless otherwise noted. 208-240V, 50/60Hz, 1Ph w/ Outlets Denotes wire splice. Reference Illustrations Cover Assembly Control Box Power Pack Assembly Hydraulic Manifold Block Electrical 6 - 15 EP800AD (Acrobat™ HPU) - Page 45 Electrical Schematic (721002) Rev A NOTE: All wires are 20 AWG unless otherwise noted. 208-240V, 50/60Hz, 1Ph w/ Outlets Reference Illustrations Cover Assembly Control Box Power Pack Assembly Hydraulic Manifold Block EP800AD (Acrobat™ HPU) 6 - 16 Electrical...
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Page 46: Hydraulic
HYDRAULIC Overview This 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. -
Page 47: Theory Of Operation (Hydraulic)
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. -
Page 48: Service And Repair
Service and Repair Check 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. - Page 49 Remove the Fluid Pick-up from the pump housing. Remove the O-ring from the cavity on the pump. Pick-up O-ring Fluid Pick-up Use a 8mm socket to remove the 4 bolts from the Hydraulic Pump. Remove the Hydraulic Pump from the Adapter Plate. Remove the O-ring from cavity in the Adapter Plate.
- Page 50 Remove the large return tube with washers and O-ring from the Adapter Plate. Install Hydraulic Pump: Install the large return tube with the washers and with a new O-ring into the Adapter Plate. Install a new O-ring onto the Hydraulic Pump. Install a new O-ring into the Adapter Plate where the Pump will mount.
- Page 51 Install the 4 Hydraulic Pump mounting bolts using a 8mm socket. Torque the mounting bolts to 10-1 1 ft-lb (13.5-15 Nm) 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.
- Page 52 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 Hydraulic Fluids section of this manual for hydraulic fluid recommendations.
- Page 53 Change Hydraulic Fluid and Filter This 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.
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Page 54: Hydraulic Symbols
PRESSURE HYDRAULIC PRESSURE HYDRAULIC GAUGE TRANSDUCER FILTER TANK Hydraulic Symbols PRESSURE GAUGE QUICK DISCONNECT RELIEF VALVE PRESSURE PRESSURE HYDRAULIC HYDRAULIC HYDRAULIC TRANSDUCER FILTER TANK HOSE GAUGE HYDRAULIC HYDRAULIC PRESSURE HYDRAULIC PRESSURE PRESSURE QUICK HYDRAULIC HYDRAULIC CHECK RELIEF NEEDLE ELECTRIC HYDRAULIC TANK GAUGE HOSE... -
Page 55: Hydraulic Schematic
Hydraulic Schematic EP800AD (Acrobat™ HPU) 7 - 10 Hydraulic... -
Page 56: Replacement Parts
This 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... -
Page 57: Hydraulic Fluid
Hydraulic Fluid The 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). -
Page 58: Previous Revisions
PREVIOUS REVISIONS Overview Previous 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 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. - Page 59 Power Pack Assembly (Revision 1 and 2) DataLogger Port Hydraulic Pressure Gauge Pressure Switch Hydraulic Manifold 10 Micron Manifold Filter Feedback Pressure Transducer Close Valve Dump Valve Open Valve Proportional Pressure Reducing Valve (PRV) EP800AD (Acrobat™ HPU) 8 - 2 Previous Revisions...
- Page 60 Manifold Block (Revision 1 and 2) Directional DIR VLV Valve Port Cartridge Filter Gauge and Transducer Port Accumulator Pressure Switch Port PS SW Port Carriage Close Port DataLogger Port ® DMP VLV Dump Valve Port Carriage Open Port PRESS CNTRL Pressure Control Valve Bleed Hose Bleed Hose...
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Page 61: Revision 2
Cover Assembly (Revision 1 and 2) Hour Meter Control Box Electrical Power Electronic Valve Receptacles Controller Revision 2 Revision 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. -
Page 62: Electrical Schematic Revision 1 And 2 (719902) Sheet A, Rev D 100-120V, 50/60Hz, 1Ph, No Outlets
Electrical Schematic Revision 1 and 2 (719902) Sheet A, Rev D 100-120V, 50/60Hz, 1Ph, No Outlets Reference Illustrations Cover Assembly Control Box Power Pack Assembly Hydraulic Manifold Block Previous Revisions 8 - 5 EP800AD (Acrobat™ HPU) -
Page 63: Electrical Schematic Revision 1 And 2 (719902) Sheet B, Rev D 100-120V, 50/60Hz, 1Ph, No Outlets
Electrical Schematic Revision 1 and 2 (719902) Sheet B, Rev D 100-120V, 50/60Hz, 1Ph, No Outlets Reference Illustrations Cover Assembly Control Box Power Pack Assembly Hydraulic Manifold Block EP800AD (Acrobat™ HPU) 8 - 6 Previous Revisions... -
Page 64: Hydraulic Schematic (Revision 1 And 2)
Hydraulic Schematic (Revision 1 and 2) Previous Revisions 8 - 7 EP800AD (Acrobat™ HPU) -
Page 65: Service And Repair (Revision 1 And 2)
Service and Repair (Revision 1 and 2) 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. - Page 66 Bleeding Air From EP800AD (Acrobat HPU) (Revision 1 and 2) Fill hydraulic reservoir according to procedure Check Hydraulic Fluid in this manual. Connect the quick disconnects together at the end of the hoses. Move the pressure selector control (A) to fusing pressure. POWER MOTOR SUPPLY...
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Page 67: Replacement Parts
This 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... -
Page 68: Post Service Function Checks
POST SERVICE FUNCTION CHECKS Post Service Function Checks Plug in HPU. Ensure dump valve is closed by turning the valve knob fully clockwise until hand tight. 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. - Page 69 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: •...
- Page 70 Set the HPUs pressure to 300psi. 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 Turn off EP800AD (Acrobat HPU).
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Page 71: Notes
NOTES Notes EP800AD (Acrobat™ HPU) 10 - 1 Notes...