Graco Inc. E P 2 1 6 0 Instructions - Parts
Instructions
Variable Frequency
Drive
Motor drive control for Graco E-Flo® Electric Circulation Pumps.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 3 for approvals information.
Part No. 15J753, 200-240 Vac
UNIDRIVE SP Digital AC Drive
208/230VAC, 5HP, SP2201
Part No. 15J754, 380-480 Vac
UNIDRIVE SP Digital AC Drive
460VAC, 5HP, SP1405
UNIDRIVE Information
311596F
Unidrives are manufactured by Control Techniques
Corporation. Read all warnings and instructions
from Control Techniques (provided on a CD)
before beginning the installation or operation of
this equipment.
Related Graco Manuals
Manual Description
311592 E-Flo Installation Manual
311593 E-Flo Operation Manual
311594 E-Flo Repair-Parts Manual
311606 VFD/BPR Air Control Manual
311608 Power Module Manual
311612 Ethernet Upgrade Kit Manual
311690 High-Flo Lowers
ti9002a
Warnings
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E-Flo Electric Circulation Pumps . . . . . . . . . . . . 3
Pump Operational Limits . . . . . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Variable Frequency Drive (VFD) Kits and Options 5
Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . 6
Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Variable Frequency Drive (VFD) Keypad . . . . . . 7
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ground the VFD . . . . . . . . . . . . . . . . . . . . . . . . . 8
Navigating the Keypad . . . . . . . . . . . . . . . . . . . . 8
E-Flo Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calibrate and Autotune the Motor . . . . . . . . . . . . 9
Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . 12
SMARTCARD Defaults . . . . . . . . . . . . . . . . . . . 12
Complete System Reload . . . . . . . . . . . . . . . . . 13
E-Flo Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Back Pressure Regulator (BPR) Control . . . . . . 15
Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Flow Rate Monitoring . . . . . . . . . . . . . . . . . . . . 16
Pressure Monitoring . . . . . . . . . . . . . . . . . . . . . 16
Operational Envelope Limit . . . . . . . . . . . . . . . . 21
Running the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 21
Secure Disable . . . . . . . . . . . . . . . . . . . . . . . . . 21
Start/Stop Command . . . . . . . . . . . . . . . . . . . . . 22
Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Drive Trip Codes and Diagnostic Procedures . . 24
Trips and Diagnostic Procedures . . . . . . . . . . . . 24
Resetting the System . . . . . . . . . . . . . . . . . . . . 24
Computer Control and Monitoring . . . . . . . . . . . . 27
Ethernet Upgrade Kit 15H885 . . . . . . . . . . . . . . 27
E-Flo Software Update . . . . . . . . . . . . . . . . . . . . . . 27
Configure the Ethernet Card . . . . . . . . . . . . . . . 30
Install the Computer Software . . . . . . . . . . . . . . 31
Connect the VFD to the PC . . . . . . . . . . . . . . . . 31
Run Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Advanced Options Screen . . . . . . . . . . . . . . . . . 35
BPR Production Flow Screen . . . . . . . . . . . . . . 36
Data Logging Screen . . . . . . . . . . . . . . . . . . . . . 39
Power Monitor Screen . . . . . . . . . . . . . . . . . . . . 40
Pressure Transducer Calibration Procedure . . . . 41
System Electrical Diagrams . . . . . . . . . . . . . . . . . 42
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mounting Hole Diagrams . . . . . . . . . . . . . . . . . . . . 45
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 46
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
2 311596F
Models
E-Flo Electric Circulation Pumps
Check your pump’s identification plate (ID) for the 6-digit part number of your
pump. Use the following matrix to define the construction of your pump, based
on the six digits. For example, Pump Part No. EP2160 represents electric
power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), 2000 cc
Maxlife lower (6), and no stand installed (0). To order replacement parts, see
the Repair-Parts manual 311594.
EP 2 1 6 0
First Digit Second Digit Third Digit Fourth Digit Fifth Digit Sixth Digit
Power
Source
E (electric) P (pump) 0 No motor 0 No circuit
Equipment
Style Motor Sensor Circuit Lower Size Stand Option
installed
1 230/400V, 5 HP,
AT EX
2 230/460V, 5 HP,
UL/CSA
3 230/400V, 3 HP,
AT EX
4 230/460V, 3 HP,
UL/CSA
1 Circuit installed 2 1500 cc Chromex 1 Stand
ID
ti8912a
ID Plate, Viewed from Above
1 1000 cc Chromex 0 No stand
installed
installed
3 2000 cc Chromex
4 1000 cc Maxlife
5 1500 cc Maxlife
6 2000 cc Maxlife
7 750 cc Chromex
Models
Pump Operational Limits
See Related Graco Manuals on the front cover.
Approvals
This equipment meets requirements of the following
approval agencies:
II2G EExdIIA T3
311596F 3
Glossary of Terms
Term Description
VFD Variable Frequency Drive
TDC Top Dead Center; measures position of pump
drive
I/O Input/output
Trip A condition which causes VFD to trip motor; see
page 24
PCB Printed Circuit Board
Pr Parameter
Run Set of commands enabling motor to run in desig-
nated direction
Stop Set of commands authorizing motor to stop run-
ning
Overview
Overview
An electric motor (B) provides input to a 75:1 gear reducer (GR), which drives two fluid pumps (FP). See FIG. 1. The
stroke positions of the two pumps are offset to achieve consistent flow from the pump assembly. See F
The optional sensor circuit includes a top dead center (TDC) sensor which assists software in measuring motor
speed, and a pressure transducer (PT) with circuit board, which measures fluid pressure at the pump outlet. The
Graco VFD software mimics the effect of a camshaft, constantly adjusting motor speed to keep steady fluid flow and
achieve minimal pressure variation. The output shaft of the gearbox and the connecting rods experience the effect of
the imaginary camshaft by speeding up when the pressure drops (pump lower is at a changeover) and slowing down
when pressure increases (both lowers are pumping).
The VFD can be controlled by a local control box mounted in the hazardous area, via communication protocol (such
as modbus), or directly from the keypad.
IG. 2.
B
FP
F
IG. 1. Electric Circulation Pump
TDC (behind
cover)
GR
PT
FP
ti8317a
ti8321a
IG. 2. Cutaway Showing Offset Stroke Positions
F
4 311596F
Variable Frequency Drive (VFD) Kits and Options
Variable Frequency Drive (VFD) Kits and Options
Kits and options can be ordered through your Graco Distributor.
Repair Kits
Transducer Kit P/N 15H876 - replaces the pressure
sensor and its circuit board. Note that pressure sensor
can be calibrated, and calibration procedure is included
in this manual.
Circuit Board Kit P/N 15H879 - replaces the sensor circuit board.
Top Dead Center Sensor Kit P/N 15H877 - replaces
top dead center (TDC) sensor.
Options
Ethernet Upgrade Kit P/N 15H885 - provides Ethernet
module for the VFD. Ethernet cable is not included.
Circuit System Kit P/N 15J755 - contains PCB and
sensors necessary to run Graco programmed VFD and
take advantage of low flow and pressure fluctuations
delivery by Graco software.
Local I/O Box P/N 120373 (UL/CSA) or 120991
(ATEX) - allows the operator to control the E-Flo locally
at the pump when performing maintenance or troubleshooting. The local I/O box has the following features:
• secure disable switch
• run/stop switch
• local/remote switch
• jog/park switch
•trip reset
Power Module P/N 288036- supplies necessary hardware to interface with the pump’s intrinsically safe (IS)
circuitry. The hardware includes IS barriers, transformer,
24 VDC power supply, fuses and terminal blocks for connectivity.
RFI Filter Module for 230 VAC VFD: P/N 120365
RFI Filter Module for 480 VAC VFD: P/N: 120366
VFD 200/240V Control Kit: P/N 15J753
VFD 380/480V Control Kit: P/N 15J754
311596F 5
Controls and Indicators
Controls and Indicators
If Local mode of operation is an option for a given installation, use Graco Local I/O Explosion Proof Control Box
(see page 5).
Two Variable Frequency Drives are available and are
used for different voltages. Use the appropriate one for
your system. See front cover for part number information.
Control Modes
There are two ways to control or monitor the E-Flo Electric Circulation Pump.
• Locally
• Remotely (Keypad/Modbus)
The addition of a local control box allows the operator to
control the E-Flo at the unit. See Available Options on
page 5.
Starting, running, and stopping of the motor is controlled
by the Sequencer, which has been programmed to comply with E-Flo Local and Remote schemes. VFDs are
normally installed in electrical enclosures, away from
motors, which they control. Local mode refers to controls which are installed locally at the pump, or within
sight of the pump. Remote mode refers to controls
installed remotely, away from the pump.
More then one command is required to be active for
motor to operate. All of these are controlled by Graco
software. Do not try to reconfigure VFD parameters to
operate outside of the Graco design described in this
manual. Doing so can cause system malfunction.
Parameters are controlled by the program in the
AppsLite module and will be reset back to E-Flo defaults
at next reset. Reset occurs during each power-up.
Run command refers to a set of commands, enabling
motor to run in designated direction.
Stop command refers to a set of commands, authorizing
motor to stop running.
Local Control Mode
When Local mode is selected, motor can only be started
by a hardware switch. VFD terminal #27 is configured
for this operation (see System Electrical Diagrams,
page 42). Normally open position is Stop; closed posi-
tion is Run.
Common ground is available at VFD terminals #1,
3, 11, 21, 23, and 30.
Mode selection is performed by a hardware switch. Digital I/O #5 (VFD terminal #28) is configured for this operation (see System Electrical Diagrams, page 42).
Normally open position of the switch commands remote
mode; closed position commands local mode.
Common ground is available at VFD terminals #1,
3, 11, 21, 23, and 30.
6 311596F
Stop Command Via Keypad
To initiate the Stop command via the keypad, press the
Stop/Reset (red) button on a keypad display.
Remote Control Mode
When remote control mode is selected, control commands can be directly entered into the VFD by means of
a keypad or can be sent via modbus. Refer to SM Ethernet User Guide (Control Techniques) for more information on modbus control.
Controls and Indicators
Variable Frequency Drive (VFD)
Keypad
The VFD keypad consists of a display, four control buttons, and a joypad with four arrow keys. See F
VFD Display
The VFD display has two rows.
The upper row (A) displays either the drive status (run is
shown) or the parameter being viewed, in the format
XX.XX (for example, 20.05). In this manual, parameters
are referred to as Pr (for example Pr 20.05).
The lower row (B) displays the parameter value (152 is
shown) or a trip code.
Table 1 shows some examples of drive status codes.
Refer to the User’s Guide by Control Techniques for the
full list.
Table 1: Drive Status Examples
IG. 3.
VFD Control Buttons
• Fwd/Rev (U): not active in this application.
• Stop/Reset (V)
• Start (I, green): not active in this application.
• Mode (M, black): used to change between the display modes - parameter view, parameter edit, status.
• Joypad: used to navigate the parameter structure
and change parameter values. See page 8 for
details.
A
B
Display Code Definition
Auto tunE
(flashes alternately)
inh VFD is inhibited and will not
rdY Motor is ready to run.
run Motor is running.
triP VFD has tripped. Trip code
dEC Decelerating - motor speed is
Motor auto tune is in progress.
run because Secure Disable
is engaged.
appears in lower display.
ramping to zero following a
stop command.
U
M
V
FIG. 3: Variable Frequency Drive Keypad
I
Joypad
311596F 7
Setup
Setup
Ground the VFD
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit. Ground the variable
frequency drive through a proper connection to a power
source. Refer to the Control Techniques manuals for
grounding instructions.
Navigating the Keypad
The Unidrive SP User Guide has a detailed explanation
of the Keypad operation and contains navigation procedures. The following is an example and is not intended
to explain in detail the complete operation of the Keypad. It is strongly recommended that the installer refer to
the Unidrive SP User Guide (provided on a CD) for
detailed instructions.
Calibration of lower size is chosen as an example to
explain the operation of the Keypad display. Graco
default setting for the lower size is 2000cc. In the following example, we will change the lower size to 1500cc.
2. Alter the value of Pr 20.03:
While number 20.03 is flashing on the upper row of
the screen, number 2000 is displayed on the lower
row of the screen, representing lower size of
2000cc.
a. Press the (M) key once. This will cause the cur-
sor to move to the bottom row of the display and
the least significant digit of the number 2000
(most right digit) should be flashing.
b. Press the Left arrow key to navigate to the third
digit from the right 20
to start flashing.
c. Press the Up arrow key to scroll to number 5.
This should cause number 25
screen with number 5 still flashing.
d. Press the Left arrow key to navigate to the next
digit on the left. This will cause number ‘2’ to
start flashing (2
e. Press the Down arrow key to change the num-
ber 2 to number 1. Number 1
played on a screen with number 1 flashing.
f. Press the (M) key once to move cursor from the
bottom row to the top row. This will cause number 20.03 on the top row to flash.
00. This will cause the digit
00 to display on a
500).
500 should be dis-
Each parameter consists of a menu number and submenu number. Lower size calibration value is located in
Pr 20.03: 20 refers to Menu 20; 03 refers to Submenu
03.
1. Navigate to Pr 20.03:
a. Pressing the Left and Right arrow keys will allow
you to navigate between menus 0 and 22.
b. Pressing the Up and Down arrow keys will allow
you to navigate within the submenus.
c. Press the Left or Right arrow keys until you
reach menu 20 (Number 20.00 should be flashing on a screen).
d. Press the Up or Down arrow keys until you
reach submenu 3 (Number 20.03 should be
flashing on a screen)
8 311596F
g. This completes the procedure of changing a
parameter value. In this case you have changed
Pr 20.03 from 2000 to 1500 (number 1500 will
show on lower row of display).
M
V
F
IG. 4: Variable Frequency Drive Keypad
Joypad
E-Flo Calibration
CAUTION
The system must be calibrated before start-up. Failure
to calibrate will result in malfunction, alarm trips, and
decreased safety.
E-Flo Calibration
pressure performance for low flow settings (corresponding motor frequency of less than 12 Hz).
5. Continue with step 1. Pressure Sensor Calibration
on page 10.
Calibrate and Autotune the
Motor
IMPORTANT: Before installing the motor it must be
calibrated and autotuned. This allows the drive to
have better control of the motor.
Graco Motors
To calibrate and autotune motors purchased from
Graco, perform the following steps:
1. Motor Selection. Parameter Pr 20.37 is reserved
for the motor calibration information listed on the
pump’s identification plate. The value of Pr 20.37 is
determined as follows:
EP1XXX=> Pr 20.37 = 1
EP2XXX=> Pr 20.37 = 0
EP3XXX=> Pr 20.37 = 4
EP4XXX=> Pr 20.37 = 3
2. Load Graco Motor Defaults. Navigate to Pr 20.16
and set its value to 56. At this time the specific
Graco motor parameters will be loaded and the
number 56 will be replaced by 0 automatically.
3. Follow the instructions under Autotune the Motor,
page 10.
IMPORTANT: Autotuning the motor is especially
important if using a 3HP motor, or if a 5HP motor is
used on a system with a low flow setting (corresponding frequency of less than 12 Hz).
Non-Graco Motors
Graco does not support the use of the Graco VFD
CAM mode on motors not supplied by Graco.
Use only 1500 rpm or 1800 rpm rated motors.
To calibrate and autotune motors not purchased from
Graco, perform the following steps:
1. Motor Selection. Set Pr 20.37 to 2 (non-Graco
motor).
2. Set Motor Parameters. Navigate to menu #5. Refer
to your motor’s identification plate for necessary
information.
a. Pr 5.06 - Rated Frequency.
b. Pr 5.07 - Motor Rated Current.
c. Pr 5.08 - Rated Load RPM/Rated Speed.
d. Pr 5.09 - Rated Voltage.
e. Pr 5.10 - Rated Power Factor.
f. Pr 5.11 - Number of Motor Pole Pairs (4 pole
motor has 2 pairs).
3. Enter Motor Rated Current. Multiply motor rated
current found on motor’s identification plate by 10.
Enter resulting value into Pr 20.12.
4. Follow the instructions under Autotune the Motor,
page 10.
4. Pr 5.27 controls the Slip Compensation feature. It is
turned on by default for 3HP motors and turned off
for 5HP motors. Turning this feature on will improve
311596F 9
5. Continue with step 1. Pressure Sensor Calibration
on page 10.
E-Flo Calibration
Autotune the Motor
IMPORTANT: Before installing the motor it must be
calibrated and autotuned. This allows the drive to
have better control of the motor.
Refer to the User’s Guide by Control Techniques for
complete autotuning instructions.
The motor shaft will rotate during autotuning. Keep
clear of moving parts.
1. Decouple motor from gearbox. Secure motor to prevent it from jumping during autotuning.
2. Apply power to motor. Motor will rotate during autotuning. Keep clear of motor shaft and moving parts.
3. Navigate to Pr 5.12 and set its value to 2.
4. Apply Run command, see page 22. Autotuning will
begin.
5. When motor stops turning, check that Pr 5.10
(Power Factor) and Pr 5.17 (Stator Resistance) are
set to non-zero values. This indicates that the autotune was successful.
To prevent accidental change of pressure sensor calibration parameters, they are locked by Pr 20.16. To
enter calibration parameters, perform the following
steps:
a. Set Pr 20.16 to 777, to unlock pressure sensor
parameters.
b. Select and set TDC and pressure transducer
function (software level 5.00.00 and later only):
• TDC: Pr 8.11. Select On (enable) or Off
(disable).
• Pressure Transducer: Pr 7.13. Select On
(enable) or Off (disable).
• Select Analog Signal Mode: Pr 7.11. Typi-
cally 4-20tr.
c. Enter calibration parameters Pr 20.34, 20.35,
and 20.36.
d. Set Pr 20.16 to 0 to lock parameters, then set
Pr 0.00 to 1001 to save parameters.
If pressure sensor is part of the system (EPX1XX –>
Fourth Digit = 1), calibration information is printed on the
label located on the circuit board cover. If the system
was purchased without a Circuit System Kit (Graco P/N:
15J755) but one was installed later, affix the label
(included with the kit) to the circuit board cover and
enter calibration information into the VFD.
6. To save motor parameters, navigate to Pr 5.00, set
its value to 1001, and press the red Stop/Reset button. The number 1001 will automatically change to
0, indicating that the parameters have been saved.
1. Pressure Sensor Calibration
IMPORTANT: Pressure sensor information for your
system is listed on the label attached to the pump
gearbox circuit board cover.
CAUTION
Pressure sensor calibration information must be
entered into the VFD. Failure to do so will result in
Pressure Sensor Calibration Trip (#50), nuisance
trips, or system malfunctions.
Pressure sensor information (Pr 20.34, 20.35, and
20.36) for your system must be keyed into the Vari-
able Frequency Drive before system start-up.
Calibration Parameters from the label:
Pr 20.34 – Zero Calibration
Pr 20.35 – Calibration Pressure
Pr 20.36 – High Calibration
2. Pump Lower Size Selection
Parameter Pr 20.03 is reserved for the Lower size calibration information listed on the unit’s identification
plate:
EPXX1X => Pr 20.03 = 1000
EPXX4X => Pr 20.03 = 1000
EPXX2X => Pr 20.03 = 1500
EPXX5X => Pr 20.03 = 1500
EPXX3X => Pr 20.03 = 2000
EPXX6X => Pr 20.03 = 2000
EPXX7X => Pr 20.03 = 750
If the pump lowers are changed to a different size
after purchase, the plate information is no longer
valid.
10 311596F
E-Flo Calibration
3. Unit Selection
Select measuring units in parameter Pr 20.15. The
default is English.
English => Pr 20.15 = 0
Metric => Pr 20.15 = 1
Measurement unit summary:
Measurement English Metric
Pressure psi bar
Flow gpm lpm
The Keypad display does not show a decimal point.
T
ABLE 2 provides resolution values for measure-
ment setting parameters.
4. High Pressure Alarm Setting
The High Pressure Alarm setting is controlled by parameter Pr 20.09. The default unit is English and default setting is 300 psi. Refer to T
allowable setting for a given Lower size and units. The
High Pressure Alarm (#40) becomes active when system pressure reaches the pressure setting in Pr 20.09.
ABLE 2 to determine maximum
Low Pressure Alarm Disable => Pr 20.08 = 0
This feature is disabled by default.
6. Low Pressure Alarm Setting
The Low Pressure Alarm setting is controlled by parameter Pr 20.07. The default unit is English and default setting is 150 psi. Refer to T
allowable setting for a given Lower size and units. The
Low Pressure Alarm (#41) becomes active if it is
enabled (Pr 20.08 = 1) and system pressure drops lower
than the Low Pressure Alarm setting.
For metric units, multiply the desired pressure by
10 and enter the result into the VFD. The last digit
is a decimal.
System pressure must first rise above the Low
Pressure Alarm setting for the trip to start operating. This allows the system to build up to operating
pressure without shutting down due to Low Pressure Alarms.
ABLE 2 to determine maximum
7. System Ramp Rate Selection
For metric units, multiply the desired pressure by
10 and enter the result into the VFD. The last digit
is a decimal.
5. Low Pressure Alarm
Enable/Disable
Low Pressure is an adjustable feature. Parameter Pr
20.08 is used to enable and disable the feature:
Low Pressure Alarm Enable => Pr 20.08 = 1
Ramp rate controls the time it takes for the pump to
reach the preset rate. Units is English, measured in gallons per minute/minute (gpm/min). Note that a fast ramp
rate may cause the pump to rapidly build high system
pressure, causing system shutdown due to a High Pressure Trip (Alarm #40).
The Ramp Rate setting is controlled by parameter Pr
20.02. Ramp rate range is 10 – 1000 gpm/min. Any
number within this range can be selected. It is recommended that the default ramp rate be kept. The default
setting is 100gpm/min.
311596F 11
E-Flo Calibration
8. Speed Potentiometer
Enable/Disable
Variable resistor (potentiometer) is used to control motor
frequency. Refer to Motor Speed Control, page 23, for
more information. Set Pr 20.38 to enable or disable the
speed potentiometer. Disable is the default.
• Speed Potentiometer Enable=> Pr 20.38 = 1
• Speed Potentiometer Disable=> Pr 20.38 = 0
9. Saving Calibration
The last step in the calibration procedure is to save all
calibration values.
a. Saving to the Drive/Program Module.
To ensure that all calibration values are permanently saved to the drive/program module:
1. Navigate to Pr 0.00 and set its value to
1001.
Factory Defaults
E-Flo System Specific Parameters (menu 20 parameters)
All of the E-Flo features are controlled by menu 20
parameters. VFDs are shipped with these parameters
set to default values (refer to Table 2 for more information). Factory defaults can be loaded as follows:
1. Disable the drive through Secure Disable (if a Graco
Local Control Box is used, press the red
mushroom-type Secure Disable button).
2. Navigate to Pr 20.16 and set its value to 1234. At
this time the program defaults will be loaded and
number 1234 will automatically be replaced by 0.
E-Flo Motor Specific Parameters
VFDs are shipped with all motor parameters defaulted to
UL/CSA motor. It is essential for system performance
that proper motor calibration parameters are entered
into the VFD. See page 9 for more information.
2. Press the red Stop/Reset button. The
number 1001 will automatically change to
0, indicating that all parameters have been
saved.
b. Saving to the SMARTCARD.
SMARTCARD is an excellent memory
backup for system-specific parameter calibrations. If system parameters are mistakenly
altered, using SMARTCARD can restore initial calibration.
1. Ensure that SMARTCARD is installed in
the VFD. (VFD is shipped with SMARTCARD already installed and Graco
defaults saved to memory location #101).
2. Navigate to Pr 0.00 and set its value to
4202 (memory location #202).
3. Press the red Stop/Reset button. Small
red dot on keypad display will start blinking, indicating that parameters are being
saved.
To restore factory defaults, set Pr 20.16 to 45.
SMARTCARD Defaults
Default Graco parameter values for menus 0 through 22
are saved on SMARTCARD in location #101, as differences from the drive defaults; see the Control Techniques manual for further information. Use Code 6101 to
load Graco defaults.
4. When dot stops blinking, the save is completed.
12 311596F
E-Flo Calibration
Complete System Reload
A complete system reload may be necessary because
of an error in calibration or accidental parameter alteration.
1. Disconnect power to the VFD.
2. Remove all solutions modules. Reconnect power.
3. Navigate to Pr 0.00 and set its value to 1244.
4. Press the red Stop/Reset button. Number 1244 will
be automatically replaced by 0 as an indication that
all VFD parameters are reset to defaults.
5. Navigate to Pr 0.00, set its value to 1001, and press
red Stop/Reset button to save the changes. Number
1001 will be automatically replaced by 0.
6. Disconnect power from the VFD, reinstall all modules, and reconnect power. Reset any faults associated with solutions modules (VFD may not
recognize modules upon first power-up). Navigate to
Pr 0.00, set its value to 1001, and press red
Stop/Reset button.
7. Navigate to Pr 17.20 and set it to ON.
8. Navigate to Pr 17.21 and set it to ON.
9. Navigate to Pr 17.00, set its value to 1001, and
press red Stop/Reset button. Number 1001 will be
automatically reset to 0 as an indication that
changes have been saved.
10. Load system-specific calibration from the SMARTCARD (if saved at initial calibration).
a. Graco defaults are loaded as differences from
VFD defaults in memory location #101. Navigate to Pr 0.00, set its value to 6101, and press
red Stop/Reset button.
b. Recommended memory location for customer
calibration is #202. Navigate to Pr 0.00, set its
value to 6202, and press red Stop/Reset button.
11. If SMARTCARD is not available or if initial calibration was not saved to SMARTCARD, perform the following steps:
a. Load Graco system defaults - set Pr 20.16 to
1234.
Saving parameters will allow the VFD to retain
information associated with solutions modules.
b. Repeat E-Flo Calibration, beginning with Cali-
brate and Autotune the Motor on page 9 and
continuing with steps 1-9 of the calibration procedure (pages 10-12).
311596F 13
E-Flo Features
E-Flo Features
Drive Active (System ON) Output
VFD Relay output is available at VFD terminals 41 and
42. The output can be mapped to most of the parameters. The most common is Drive Active. This relay output
will be closed when drive is active (there will be continuity between terminals 41 and 42). Pr 8.27 controls the
relay source. In case Drive Active is a desired source,
navigate to Pr 8.27 and set it to 10.02.
Pr 10.02 is a Drive Active indicator. See the Control
Techniques manual for further information.
Jog Mode
Jog mode allows the user to run the pump at the slow
speed and to stop it at a desired position. Note that park
angle allows easy access to the stand-side lower. Jog
mode can therefore be used to stop the pump at an
angle which will allow easy access to the motor-side
lower. Jog speed is equivalent to the following flow rates:
2000cc lowers: 2.7 gpm (10.2 lpm)
1500cc lowers: 1.9 gpm (7.3 lpm)
1000cc lowers: 1.4 gpm (5.4 lpm)
750cc lowers: 1.0 gpm (3.8 lpm)
Jog Mode in Local Control
Operation
To initiate Jog mode, press and hold the jog button. Jog
mode will stay active as long as the jog button is
pressed. When the jog button is released, the system
will stop.
Jog Mode - Keypad / Modbus Control
Parameter Pr 20.01 is allocated to control system
modes. Jog mode is mode #2. In order to initiate jogging, navigate to Pr 20.01 and set its value to 2. At this
time the system will enter the Jog mode.
When the pump has reached the desired position, stop
the system using one of the following methods:
• Put the system in Park by setting Pr 20.01 to 3, or
• Initiate the Stop command by using the red
Stop/Reset button or via Pr 20.25 (see Running the
Pump on page 21 for details).
IMPORTANT: Once system is stopped and jogging
is no longer required, change Pr 20.01 back to 0 to
revert to Cam mode.
Park Mode
Park mode allows you to park the pump in a position
allowing easy access to stand-side lower.
Hardware
Jog mode requires a momentary, normally open switch.
Graco offers a control box with jog switch installed. If
local control box is used and Local/Remote switch is set
to Local, jog mode can be initiated by pressing momentary “Jog” switch. Digital I/O #6 (VFD terminal #29) is
configured for the Jog mode (see System Electrical
Diagrams, page 42). Normally open (N.O.) position of
the switch disables jogging and closed position of the
switch (VFD terminal #29 connected to common)
enables jogging.
14 311596F
Park Mode in Local Control
Jog button has a dual function – Jog and Park. To
access the Park mode, press and release the switch in
less than 1 second.
Park Mode – Keypad / Modbus Control
Parameter Pr 20.01 is allocated to control system
modes. Park mode is mode #3. To initiate parking, navigate to parameter Pr 20.01 and set its value to 3. The
system will enter the Park mode. See Jog Mode instructions.
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