Graco 334359E, E-Flo DC 2000, 3000, and 4000 Circulation Pumps Instructions

Typical Installation, page 11 .

Installation of this equipment involves potentially hazardous procedures. Only trained and qualified personnel who have read and who understand the information in this manual should install this equipment.

During installation pumps could slide together causing a potential pinch hazard. Use caution when installing the pumps.

When selecting the location for the equipment, keep the following in mind:

• There must be sufficient space on all sides of the equipment for installation, operator access, maintenance, and air circulation.

• Ensure that the mounting surface and mounting hardware are strong enough to support the weight of the equipment, fluid, hoses, and stress caused during operation.

• There must be a start/stop control (C) within easy reach of the equipment.

See

Place each pump (4) onto the stand frame (6) and align the mounting holes of the motor stand bracket (2) with the stand frame (6). Install washers (13) and bolts (14) but do not tighten.

Install the bottom manifold (3). Place gaskets

(15) over the bottom of the pump lowers and attach manifold (3) using clamps (7).

Install the top manifold. Place gaskets (15) over the top of the pump lowers and attach manifold

(3) using clamps (7).

Install the o-ring (34c) and pressure transducer

(34b) on the transducer manifold (34a). Use the gasket (34e) and clamp (34d) to attach the transducer assembly to the top manifold (3).

Tighten bolts (14) to secure the pumps to the stand.

Install the shields (12) on both pumps by engaging the bottom lips with the groove in the wet cup cap. Snap the two shields together.

See

Mounting Hole Patterns, page 54 . Secure

the stand to the floor with M19 (5/8 in.) bolts which engage at least 152 mm (6 in.) into the concrete floor to prevent the pump from tipping.

Level the stand as required, using shims.

When lifting the full assembly use the lift rings on both motors. Failure to use both lift rings will cause the pump to become unbalanced, make it difficult to move, and could result in damage to the assembly.

334359E 7

Figure 1 Mount the Pump

8 334359E

Shut off and lock out power to the motor.

Assemble the bracket kit (6a-6f) and the holder and tie (11, 12) as shown.

Install the module (1) in the bracket (6a), making sure the tabs at the bottom of the bracket engage the slots in the module, and the lip at the top of the bracket holds the module securely in place.

If still on, shut off and lock out power to the motor.

Connect the gray end of the accessory cable (25) into port 3 on the bottom of the control module.

Use the tie (12) as a strain relief. Connect the red end of the accessory cable (25) into power terminal (PT) 1 on the first motor.

Plug the gray end of the second accessory cable

(25) into PT 2 on the first motor and the red end of the accessory cable (25) into PT 1 on motor 2.

Install the jumper connector (5) over PT 2 and

PT 3 on motor 2, using the screw (5a).

Restore power to the motor.

Figure 2 Install the Control Module

Figure 3 Connect the Control Module

334359E 9

Typical Installation, page 11

Improper wiring may cause electric shock or other serious injury if work is not performed properly.

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

See Table 1 for power supply requirements for each individual motor. The system requires a dedicated circuit protected with a circuit breaker.

All electrical wiring in the hazardous area must be encased in Class I, Division I, Group D approved explosion-proof conduit. Follow all National, State, and Local electric codes.

A conduit seal (D) is required within 18 in. (457 mm) of the motor for the US and Canada. See

All cables must be rated at 70°C (158°F).

Model Voltage Phase

All EC

Models

200–240

Vac

1 50/60

5.8 kVA (2.9

kVA per motor)

Use appropriate conduit, connectors, and cable glands rated for ATEX II 2 G. Follow all National,

State, and Local electric codes.

All cable glands and cables must be rated at 70°C

(158°F).

10 334359E

Electrical Supply (must be sealed conduit approved for use in hazardous locations)

Fused Safety Switch, with lock

Start/Stop Control (must be approved for use in hazardous locations)

Explosion Proof Conduit Seal. Required within 18 in. (457 mm) of the motor for the

US and Canada.

Fluid Pressure Gauge

Fluid Shutoff Valve

Pump Ground Wire. Two ground terminals are provided if local code requires redundant grounding connections.

Fluid Drain Valve

334359E 11

Power Supply Connections, page 13

Improper wiring may cause electric shock or other serious injury if work is not performed properly.

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Ensure that the fused safety switch (B) is shut off and locked out.

Install a start/stop control (C) in the electrical supply line (A), within easy reach of the equipment. The start/stop control must be approved for use in hazardous locations.

wired to operate two motors. See

Open the electrical compartment (S) on the motor.

Bring the power wires into the electrical compartment through the 3/4–14 npt(f) inlet port.

Connect the wires to the terminals, as shown in

Power Supply Connections, page 13

. Torque the

Close the electrical compartment. Torque the cover screws to 15 ft-lb (20.3 N•m).

Repeat the steps above for the second motor.

12 334359E

Lock Out

Box

GND

P 1

P 2

Lock Out

Box

GND

P 1

P 2

Motor 2

P 1

P 2

P 1

P 2

Motor 1

Lock Out box

GND

P 1

P 2

Motor 2

P 1 P 2 P 1

P 2

Motor 1

Tighten all terminal nuts to 25 in-lb (2.8 N•m) maximum.

Do not over-torque.

Tighten cover screws to 15 ft-lb (20.3 N•m).

A conduit seal (D) is required within 18 in. (457 mm) of the motor for the US and Canada.

334359E 13

Typical Installation Diagram, page 11 , using

Install the following accessories in the order shown in the

adapters as necessary.

This equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Pump: Loosen the ground screw and attach a ground wire. Tighten the ground screw securely.

Connect the other end of the ground wire to a true earth ground.

to the maximum working pressure of 400 psi (2.8

MPa, 28.0 bar).

relieve fluid pressure in the hose and circulation system.

adjustment of the fluid pressure.

control module and must be grounded to the same ground point. Different ground points

(unequal potential) may cause current to flow through component cables, causing incorrect signals.

Before using the equipment, open the fill cap (P) and add Graco Part No. 16W645 ISO 220 silicone-free synthetic gear oil. Check the oil level in the sight glass

(K). Fill until the oil level is near the halfway point of the sight glass. The oil capacity is approximately 1.5

supplied with the equipment.

Fluid hoses with a maximum of 500 ft. (150 m) combined hose length to ensure grounding continuity. Check the electrical resistance of hoses. If total resistance to ground exceeds 25 megohms, replace hose immediately

Fluid

14

The pump fluid section was tested with lightweight oil, which is left in the fluid passages to protect parts.

To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment.

334359E

Pressure Relief Procedure, page 15 .

To operate the pump, follow the Startup instructions for the Advanced motor in the Motor manual.

Run the pump at a slow speed until the fluid lines are primed and all air is forced out of the system.

The Control Module provides the interface for users to enter selections and view information related to setup and operation.

The screen backlight is set to turn off after 10 minutes of inactivity.

Keys are used to input numerical data, enter setup screens, navigate within a screen, scroll through screens, and select setup values.

Follow the

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from splashing fluid and moving parts, follow the

Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

Disengage the start/stop control (C).

See

Typical Installation, page 11 .

Shut off and lock out the fused safety switch (B).

Open the fluid drain valve (H), having a waste container ready to catch drainage. Leave open until you are ready to pressurize system again.

Fiber Optic RX - to PLC

Fiber Optic TX - to PLC

Power and CAN communication

Start/stop input

Fiber Optic RX - to next ADCM

Fiber Optic TX - to next ADCM

Pressure transducer 1

BPR control 4-20mA output

Agitator control 4–20 mA output

Pressure transducer 2

334359E 15

Setup Screens, page 26 , explain what each icon

The Control Module has two sets of screens:

Run and Setup. For detailed information see

Run Screens, page 22

, and

Setup Screens, page 26 .

Press to toggle between the Run screens and the Setup screens.

The above image shows a view of the control module display and keys.

To prevent damage to the softkey buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

Table 2 explains the function of the membrane keys on the control module. As you move through the screens, you will notice that most information is communicated using icons rather than words to simplify global communication. The detailed screen descriptions in

Run Screens, page 22

, and

represents. The two softkeys are membrane buttons whose function correlates with the screen content to the immediate left of the button.

16 334359E

Setup Screen 14, page 39 .

Press to toggle between Run screens and Setup screens.

Enter Screen.

Highlight data that can be edited.

Also changes the function of the Up/Down arrows so they move between data fields on the screen, rather than between screens.

Error Reset:

Use to clear alarm after cause has been fixed. When there is no alarm to clear, this key will set the active pump’s profile to Stop. Also used to cancel data entered and return to original data.

Exit Screen.

Exit data editing.

Up/Down Arrows:

Use to move between screens or fields on a screen, or to increment or decrement the digits in a settable field.

Enter.

Press to activate a field for editing or to accept the highlighted selection on a dropdown menu.

Softkeys:

Use varies by screen.

See columns at right.

Right.

Move to the right when editing number fields. Press again to accept the entry when all digits are correct.

Reset.

Reset totalizer to zero.

Activate Profile.

This softkey is disabled by default, and only appears if the “Profile Lock” box is checked on

Press to activate the profile just edited.

Search.

Press in Run Screen 1 to make the active pump blink for identification.

334359E 17

Run Screens, page 22 , and

As you move through the screens, you will notice that most information is communicated using icons rather than words to simplify global communication. The detailed screen descriptions in

Setup Screens, page 26

, explain what each icon represents.

Speed

Pressure Control

Pump Pressure

Pressure

In Setup Mode

Pressure Mode

Lower Size

Maximum

Limit

Maximum and

Minimum Limits

Alarm Enable

Jog Mode

Profile Number

Cycles

Flow Rate

Target

Mode Select

Flow Mode

Back Pressure

Regulator

Minimum

Limit

Deviation Enable

Calibration

Jog Up/Down

Cycles Total Volume

Units

Maintenance

Transducer

Calibration Scale

Serial Number

Pressure Transducer Off

Zero Offset

Local Control

Control Location

PLC/Remote Control

Modbus Address

Modbus Device

Serial Port

Serial Baudrate

Calendar Clock

Lock Profile

Password

Enable Agitator Output

Agitator Speed Setting

Actual VFD Frequency Disable PLC/Network Control

18 334359E

Setup Screen 14, page 39 .

Refer to this section if you have questions about screen navigation or about how to enter information and make selections.

Use to move between screens.

Press to enter a screen. The first data field on the screen will highlight.

Use change.

Press to highlight the data you wish to to edit.

The reset field is used for totalizers. Press reset the field to zero.

When all data is correct, press

Then use to move to a new screen, or to to exit the screen.

to move between Setup screens and Run screens.

Use to highlight the correct choice from the dropdown menu.

Press to select.

Press to cancel.

Screens 1 through 4, you must set up the system parameters in Setup Screens 5 through 14, as follows.

Press to enter the Setup screens. Setup

Screen 1 will appear.

Scroll to Setup Screen 5.

The first digit will be highlighted. Use to change the number.

Press to move to the next digit.

When all digits are correct, press accept.

Press to cancel.

again to

A check box field is used to enable or disable features in the software.

Press box.

to toggle between and an empty

The feature is enabled if a is in the box.

See

Setup Screen 5, page 32

, and select the lower used in your system.

Continue setting the system parameters on

Setup Screen 6, page 33

through

Scroll to Setup Screen 1. Establish the profiles for each pump. See

Setup Screen 1, page 26

through

When the profiles are set to achieve the desired pressures and flow rates, start the pump. Go to

Setup Screen 5, page 32

. Check the box next to to perform an automatic system calibration.

The system will learn its optimum settings over

21 cycles.

334359E 19

20 CONTINUED ON THE NEXT PAGE.

334359E

334359E 21

Appendix A - Modbus Variable Map, page 56 .

The Run screens display current target values and performance for a selected profile. Any alarms will display in the sidebar at the right of the screen.

Screens 5–8 display a log of the last 20 alarms.

Information displayed on the Run screens corresponds to the Modbus Registers. See

The active profile may be changed in Run Screens

1, 2, and 3.

This screen displays information for a selected profile. A box around an icon indicates which mode the profile is running (pressure or flow).

Enter the screen.

Select the desired profile (1 to 4), using the pull-down menu.

Select from the profile drop-down menu to stop the pump.

Displays pump speed in cycles per minute.

Displays pump pressure as a percentage.

If a transducer is used, this icon is replaced by the pressure icon.

Displays current flow rate, in units as selected in

Setup Screen 12, page 37 .

Exit the screen.

Figure 4 Run Screen 1

Figure 5 Select a Profile

22 334359E

This screen displays information for controlling an electric agitator via a 4–20 mA signal to a Variable

Frequency Drive (VFD).

Figure 6 Run Screen 2

Enter the screen.

Select this box to enable control output to a VFD.

Set the desired speed setpoint for the agitator, from 0 — 100 % (4–20 mA).

For example, a setting of 100% would correspond to 20 mA. A setting of 50 % would correspond to 12 mA.

Displays the actual VFD frequency.

Select this box to disable network control of the agitator.

Exit the screen.

Figure 7 Enable Control Output

Figure 8 Set Agitator Speed Setpoint

Figure 9 Actual VFD Frequency

Figure 10 Disable Network Control

334359E 23

This screen displays pressure settings for the active profile.

setup selections.

This screen displays fluid flow settings for the active profile.

setup selections.

Figure 11 Run Screen 3, in Pressure Mode

Figure 13 Run Screen 4, in Pressure Mode

Figure 12 Run Screen 3, in Flow Mode

Enter the screen.

Select the desired profile (1 to 4), using the pull-down menu.

Select from the profile drop-down menu to stop the pump.

Displays pressure maximum (first data field), target (second data field), and minimum (third data field), as selected in

Setup Screen 2, page 28

. See

to set or disable the pressure alarms.

Exit the screen.

Figure 14 Run Screen 4, in Flow Mode

Enter the screen.

Select the desired profile (1 to 4), using the pull-down menu.

Select from the profile drop-down menu to stop the pump.

The first line displays the maximum flow rate and maximum cycle rate

(displayed as a cpm conversion of the maximum flow setting). The second line displays the target flow rate. The third line displays the minimum flow rate. See

Setup Screen 3, page 29

to establish these settings. See

to set or disable the flow alarms.

Exit the screen.

24 334359E

Setup Screen 12, page 37 .

This screen displays the current pressure readings of transducers 1 and 2. Pressure can be displayed as psi, bar, or MPa. See

Run Screens 6–9 display a log of the last 20 alarms, with date and time.

Figure 16 Run Screens 6–9 (Screen 6 shown)

Figure 15 Run Screen 5

334359E 25

Screen Navigation and Editing, page 19

Use the Setup screens to set control parameters for the motor.

See

, for information on how to make selections and enter data.

Inactive fields are grayed-out on a screen.

Information displayed on the Setup screens corresponds to the Modbus Registers. See

Appendix A - Modbus Variable Map, page 56 .

1–4, do the initial setup on Setup Screens 5–14.

Screens 5–14 establish the configuration for your system and affect the displayed data.

Use this screen to set the operating mode for a profile.

Enter the screen.

Profile selection — See Step 1.

Pressure mode or Flow mode — See

Step 2.

Setting for Back Pressure Regulator —

See Step 3.

Press to accept the selections.

This softkey is disabled by default, and only appears if the “Profile Lock” box is checked on

Press to activate the profile just edited.

Exit the screen.

Figure 17 Setup Screen 1

26 334359E

Select the desired profile (1 to 4), using the pull-down menu.

Figure 18 Select Profile Number

Select the desired operating mode (pressure or flow), using the pull-down menu.

pump speed to maintain the fluid pressure percentage set on Setup Screen 2.

speed to maintain the target flow rate set on

Setup Screen 3.

Figure 19 Select Mode (Pressure Mode Shown)

If the system is equipped with a back pressure regulator (BPR) kit (P/N 24V001), set the target air pressure to the BPR from 0 to 100 percent

(approximately 1 to 100 psi). Leave the field set to 000 for a system with no BPR.

Figure 20 Set Back Pressure Regulator

334359E 27

Setup Screen 4, page 30 ,

Use this screen to set the maximum, target, and minimum fluid pressure for a selected profile. In pressure mode, you will set a target fluid pressure.

In flow mode, you will set a maximum fluid pressure.

In either pressure or flow mode, a minimum pressure may be set if desired. See

to specify how the system will respond if the pump begins to operate outside of the set boundaries.

Select the desired profile (1 to 4), using the pull-down menu.

In flow fluid pressure, as a percentage of the maximum not run if the profile does not have a maximum pressure setting. This field is not used in pressure mode.

Enter the screen.

Profile selection — See Step 2.

Fluid pressure maximum— See Step 3.

Fluid pressure target — See Step 4.

Fluid pressure minimum — See Step 5.

Press to accept the selections.

This softkey is disabled by default, and only appears if the “Profile Lock” box is checked on

Setup Screens 8 and 9, page 34

Press to activate the profile just edited.

Exit the screen.

pressure mode target as a percentage of the maximum pressure of your pump. This field is not used in flow mode.

target pressure will be displayed as a pressure value rather than a percentage of maximum pressure. See

to enable closed loop pressure control.

If desired, set a minimum pump fluid pressure, as a percentage of the maximum fluid pressure of your pump.

28 334359E

Use this screen to set your flow rate settings for a selected profile. In pressure mode, you will set a maximum flow rate. In flow mode, you will set a target flow rate. In either pressure or flow mode, a minimum flow rate may be set if desired. See Setup Screen 4 to specify how the system will respond if the pump begins to operate outside of the set boundaries.

For systems with multiple pumps and one display, select the desired pump (1 to 8), using the pull-down menu.

Select the desired profile (1 to 4), using the pull-down menu.

In not used in pressure mode.

Enter the screen to set or change preferences.

Profile selection — See Step 2.

Flow rate maximum— See Step 3.

Flow rate target— See Step 4.

Flow rate minimum — See Step 5.

Press to accept the selections.

This softkey is disabled by default, and only appears if the “Profile Lock” box is checked on

Press to activate the profile just edited.

Exit data editing.

Figure 21 Flow Mode: Flow Rate Settings

In pressure

The software will calculate the number of pump cycles needed to achieve that flow rate. This field is not used in flow mode.

not have a maximum flow rate setting.

value that can be displayed is 9999. If the field displays ####, the saved value is out of range. Go to

Setup Screen 12, page 37

and change the flow rate to a larger unit. Return to this screen and reduce the setting to a lower value that will be within the display’s range, then reset the flow rate units to cc/min.

Figure 22 Pressure Mode: Flow Rate Settings

If desired, set a minimum flow rate.

334359E 29

Use this screen to specify how the system will respond if the pump begins to operate outside of the pressure and flow settings established on Setup

Screen 2 and Setup Screen 3. The operating mode

(pressure or flow, set on Setup Screen 1) determines which fields are active.

Figure 23 Alarm Preference Menu

• / Limit: The pump continues to run and issues no alert.

– Maximum pressure set to Limit: The system reduces the flow if necessary to prevent the pressure from exceeding the limit.

– Maximum flow set to Limit: The system reduces the pressure if necessary to prevent the flow from exceeding the limit.

– Minimum pressure or flow set to Limit: The system takes no action. Use this setting if no minimum pressure or flow setting is desired.

• problem, but the pump may continue to run past the maximum or minimum settings until the system’s absolute pressure or flow boundaries are reached.

• cause and shuts down the pump.

Enter the screen to set or change preferences.

Pressure Alarm Enable

Line 1 (Pressure Maximum): use dropdown menu to set as Limit,

Deviation, or Alarm.

Line 2 (Pressure Minimum): use dropdown menu to set as Limit,

Deviation, or Alarm.

Flow Rate Alarm Enable

Line 3 (Flow Maximum): use dropdown menu to set as Limit, Deviation, or Alarm.

Line 4 (Flow Minimum): use dropdown menu to set as Limit, Deviation, or Alarm.

Press to accept the selections.

This softkey is disabled by default, and only appears if the “Profile Lock” box is checked on

Press to activate the profile just edited.

Exit data editing.

Figure 24 Setup Screen 4 (In Pressure Mode)

Figure 25 Setup Screen 4 (In Flow Mode)

30 334359E

maximum flow to Alarm. If the flow rate exceeds the maximum entered on Setup Screen 3, an Alarm symbol shut down.

will show on screen and the pump will choose to set the minimum flow to Deviation. If the flow rate drops below the minimum entered on

Setup Screen 3, a Deviation symbol will show on screen to warn the user that action should be taken. The pump continues to run.

the minimum pressure to Alarm. If a hose bursts, the pump will not change speed, but the back pressure will fall. When the pressure falls below the minimum entered on Setup Screen 2, an Alarm symbol shut down.

will show on screen and the pump will choose to set the maximum pressure to Limit to prevent the connected equipment from excessive pressure.

choose to set the maximum pressure to Deviation.

When the pressure exceeds the maximum entered on Setup Screen 2, a Deviation symbol will show on screen to warn the user that action should be taken. The pump continues to run.

334359E 31

Use this screen to set the lower pump size (cc) of the system. The default is blank; select the correct lower size. This screen also activates jog mode, allowing you to position the motor/pump shaft for connection or disconnection. The screen also allows you to initiate an automatic system calibration when the pump is running a profile.

Figure 29 Initiate Automatic System Calibration

Figure 26 Setup Screen 5 initiated, the system causes the display to bring up a new screen for showing the progress of the calibration. The progress bar increments with each pump cycle. The display returns to Setup

Screen 5 when the calibration is complete or is stopped manually. Press calibration.

or to cancel the

Figure 27 Select Jog Mode

Figure 28 Select Pump Lower

Enter the screen.

Select to enable jog mode. Use the arrow keys to move the motor/pump shaft up or down.

Select the correct pump lower size from the drop-down menu. The default is blank. If custom is selected, a field will open to input the size of the lower in cc.

Select to initiate automatic system calibration. The pump must be running a profile prior to selection for the calibration procedure to work.

Press to accept the selections.

Exit the screen.

32 334359E

Use this screen to view the grand totalizer value and set or reset the batch totalizer.

Use this screen to set the desired maintenance interval (in cycles) for each pump. The screen also displays the current cycle count. An Advisory is issued when the counter reaches 0 (zero).

Figure 30 Setup Screen 6

Figure 31 Reset the Totalizer

Enter the screen to set or change preferences.

Grand Totalizer - displays the current grand total of pump cycles. Not resettable.

Batch Totalizer - displays the batch total in selected volume units.

Reset Batch Totalizer - resets the batch totalizer to zero.

Press to accept the selections.

Exit data editing.

Figure 32 Setup Screen 7

Enter the screen.

Set the desired maintenance interval (in cycles) for each pump.

Press to accept the selections.

Exit the screen.

334359E 33

Use these screens to set up the pressure transducers.

The screens are identical, except Screen 8 is for transducer 1 and Screen 9 is for transducer 2.

Selecting a transducer and checking the pressure control checkbox activates closed loop pressure control.

Figure 34 Select Pressure Transducer

Figure 33 Setup Screens 8 and 9 (Screen 8 shown)

Figure 35 Closed Loop Pressure Enable

Select from the dropdown options to enable the transducer.

Enables the pump to use the transducer to control to a pressure setpoint

(psi/bar/mpa, rather than %force)

Enter the calibration scale factor from the transducer label.

Enter the calibration offset value from the transducer label.

Displays the current transducer reading.

Exit data editing.

Move between Setup Screens, fields on a screen, or to increment/decrement the digits when editing number fields.

Figure 36 Enter Calibration Scale Factor

Figure 37 Enter Calibration Offset Value

34 334359E

This screen is auto-populated with the serial numbers and software versions for each motor.

In this system there is a ‘parent’ motor and a ‘child’ motor. The ‘parent’ motor controls itself to the active profile setpoints while the ‘child’ follows. The first serial number listed on this screen corresponds to the ‘parent’ and the second to the ‘child’.

Figure 38 Setup Screens 10 attached to the side of the motor.

Each motor can be run individually by disabling the other (X in the selection box).

334359E 35

Use this screen to set your modbus preferences.

Figure 41 Set Modbus Node ID

Figure 39 Setup Screen 11

Enter the screen.

Control location. Select local remote or control from the dropdown options. Setting applies to the selected pump only.

Enter or change the Modbus node ID.

Value is between 1 and 247. Each pump requires a unique node ID, which identifies that pump if more than one pump is connected to the display.

Select serial port baud rate from the dropdown options: 57600 or 115200.

This is a system-wide setting.

Press to accept the selections.

Exit data editing.

Figure 42 Set Baud Rate (Bits Per Second) which cannot be set or changed by the user: 8 data bits, 2 stop bits, no parity.

Figure 40 Select Local or Remote Control

36 334359E

Use this screen to set the desired units for pressure, totals, and flow.

Figure 44 Select Desired Pressure Units

Figure 43 Setup Screen 12

Select desired pressure units (psi, bar, or MPa)

Select desired volume units (liters or gallons)

Select desired flow rate units (L/min, gpm, cc/min, oz/min, or cycles/min)

Exit data editing.

Move between Setup Screens, fields on a screen, or to increment/decrement the digits when editing number fields.

Figure 45 Select Desired Volume Units

Figure 46 Select Desired Flow Rate Units

334359E 37

Use this screen to set your date format, date, and time.

Figure 48 Select the Date Format

Figure 47 Setup Screen 13

Enter the screen to set or change preferences.

Select your preferred date format from the dropdown menu.

MM/DD/YY

DD/MM/YY

YY/MM/DD

Set the correct date.

Set the correct time.

Check this box to reset the system to initiate a software update after the token has been inserted into the module.

Press to accept the selections.

Exit data editing.

Figure 49 Set the Date

Figure 50 Set the Time

Figure 51 Reset to Initiate a Software Update

38 334359E

Use this screen to enter a password that will be required to access the Setup screens. This screen also displays the software version.

Figure 53 Set the Password

Figure 52 Setup Screen 14

Enter the screen to set the password.

When the top box of the screen is checked, the password is active. To temporarily disable the password, uncheck the box. The password field will be grayed-out.

Enter the desired 4–digit password.

Check the box to lock out the profile field in the Run screens.

Exit data editing.

Figure 54 Disable the Password

Figure 55 Lock the Profile

Power Supply Requirements, page 10 .

334359E 39

Troubleshooting

manual for further information.

Pump output low on both strokes.

Pump output low on only one stroke.

No output.

Pump operates erratically.

Pump will not operate.

Inadequate power supply.

Exhausted fluid supply.

Clogged fluid outlet line, valves, etc.

Worn piston packing.

Held open or worn ball check valves.

Worn piston packing.

Improperly installed ball check valves.

Exhausted fluid supply.

Held open or worn ball check valves.

Worn piston packing.

Inadequate power supply.

Exhausted fluid supply.

Clogged fluid outlet line, valves, etc.

Fluid dried on piston rod.

See

Refill and reprime pump.

Clear.

Replace. See lower manual.

Check and repair. See lower manual.

Replace. See lower manual.

Check and repair. See lower manual.

Refill and reprime pump.

Check and repair. See lower manual.

Replace. See lower manual.

See

Power Supply Requirements, page 10 .

Refill and reprime pump.

Clear.

Disassemble and clean pump.

See lower manual. In future, stop pump at bottom of stroke.

40 334359E

Notes

334359E 41

Error Code Troubleshooting

Error codes can take three forms:

• Alarm : alerts you to the alarm cause and shuts down the pump.

• Deviation : alerts you to the problem, but pump may continue to run past the set limits until the system’s absolute limits are reached.

• Advisory: information only. Pump will continue to operate.

the code is associated with the display only.

code is a placeholder for the number of the pump where the event occurred.

indicator on the motor. The blink code given below indicates the sequence. For example, blink code 1–2 indicates 1 blink, then 2 blinks; the sequence then repeats.

pressure (P codes) can be designated as alarms or deviations. See

Error Code Troubleshooting

indicator of which pump is active ( softkey has been pushed, see

Run Screen 1, page 22

42

None Basic 6 Alarm

The Mode Select knob is set between Pressure and

None Basic and

Advanced

CAC_ Advanced None

CAD_

CAG_

Advanced

2–3

2–4

Flow . Set knob to the desired mode.

None A blink code of 9 is not an error code, but an indicator of which pump is active.

Alarm Display detects a loss of CAN communication. Flashing alarm appears on the display, and the blink code occurs.

Alarm Unit detects a loss of CAN communication. This alarm is only logged. No flashing alarm appears on the display, but the blink code does occur.

Alarm Display detects a loss of modbus communication when control access is set to modbus.

Alarm

Circuit board communication failure.

CCN_

Basic and

Advanced

END_ Basic and

Advanced

3–6

5–6

ENN_ Advanced

ENF_ Advanced

Advisory System calibration completed successfully.

Advisory System calibration error. System could not find the optimum settings. Check for problems in the pump lower — excess air, balls not checking, material suction difficulties, for example.

K1D_

Advanced 1–2 Alarm Flow is below minimum limit.

K2D_

Advanced None Deviation Flow is below minimum limit.

K3D_

Advanced None Deviation Flow exceeds maximum target; also indicates pump runaway condition exists.

K4D_ Basic and

Advanced

Advisory A calibration of the automatic encoder and stroke range is in progress.

Alarm Flow exceeds maximum target; also indicates pump runaway condition exists.

334359E

MND_ Advanced None Advisory Maintenance counter is enabled and countdown reached zero (0).

Advanced 1–3 Alarm Pressure is below minimum limit.

Advanced

None Deviation Pressure is below minimum limit.

None Deviation Pressure exceeds maximum target.

1–4 Alarm Pressure exceeds maximum target.

P5DX Advanced None Deviation More than one pump is assigned to a transducer. The assignment for that transducer is automatically cleared under this condition. User must reassign.

P6CA or

Advanced None Deviation For units without closed loop pressure control: Transducer (A or B) is enabled but not detected.

P6D_ Advanced 1–6 Alarm For units with closed loop pressure control: Transducer is enabled but not detected.

Alarm Internal thermistor disconnected.

T2D_ Basic and

Advanced

T3D_ Basic and

Advanced

V1I_

Basic and

Advanced

V1M_ Basic and

Advanced

3–5

2–6

Deviation Over temperature.

Alarm Brown out; voltage supplied to motor is too low.

Alarm AC power is lost.

V4I_ Basic and

Advanced

WCW_

Advanced

3 Alarm Voltage supplied to motor is too high.

0 Alarm E-Flo DC 2000, 3000, and 4000 circulation pump system key token (blue) is missing; install in token slot under back panel on side of display.

Alarm Internal software error.

WMC_ Basic and

Advanced

4–5

WNC_ Basic and

Advanced

WNN_ Advanced

3–4 Alarm Software versions do not match.

0 Alarm The system detects a display with a (blue) key token installed, but the indicated motor is not configured as an E-Flo DC

2000, 3000, 4000 x 2 system.

WSC_ Advanced None Deviation Profile is set to 0 pressure or 0 flow.

WSD_ Advanced 1–5 Alarm Invalid lower size; occurs if the unit is operated before setting up the lower size.

WXD_ Basic and

Advanced

4 Alarm An internal circuit board hardware failure is detected.

334359E 43

Performance Charts

To find the fluid pressure (psi/bar/MPa) at a specific fluid flow (gpm/lpm) and percentage of maximum force:

Locate the desired fluid flow in the scale at the bottom of the chart.

Follow the vertical line up to the intersection with the selected percentage of maximum force (see

Follow left to the vertical scale to read the fluid outlet pressure.

100%, 70%, and 40% of maximum force. These values are approximately equivalent to an air motor operating at 100, 70, and 40 psi.

100% of maximum force

70% of maximum force

40% of maximum force psi (bar, MPa)

450

(31.5, 3.15)

400

(28.0, 2.80)

350

(24.5, 2.45)

300

(21.0, 2.10)

250

(17.5, 1.75)

200

(14.0, 1.40)

150

(10.5, 1.05)

100

(7.0, 0.70)

(3.5, 0.35)

4 8 12 16 20

(7.6)

(15.2)

(22.8)

(30.4)

(38.0) recommended range for continuous-duty circulation.

44 334359E

psi (bar, MPa)

300

(21.0, 2.10)

250

(17.5, 1.75)

200

(14.0, 1.40)

150

(10.5, 1.05)

5 10 15 20

100

(7.0, 0.70)

(3.5, 0.35)

0 2

(7.6)

(15.2)

(22.8)

(30.4)

(38.0)

(45.4)

(53.0)

(60.6) recommended range for continuous-duty circulation.

psi (bar, MPa)

225

(15.7, 1.57)

200

(14.0, 1.40)

175

(12.2, 1.22)

150

(10.5, 1.05)

125

(8.7, 0.87)

100

(7.0, 0.70)

(5.2, 0.52)

(3.5, 0.35)

(1.7, 0.17)

4 8 12 16 20

(15.2)

(30.4)

(45.4)

(60.6)

(75.7) recommended range for continuous-duty circulation.

334359E

Performance Charts

45

Repair

Stop the pump at the bottom of its stroke.

Relieve the pressure. See the

Pressure Relief Procedure, page 15 .

Remove the 2-piece shield (12) by inserting a screwdriver straight into the slot, and using it as

(6) have been disassembled from the motor, see

Reassemble the Coupling Adapter and Tie Rods to the Motor, page 47 .

Assemble the coupling nut (11) to the piston rod

(R).

Orient the lower (7) to the motor (3). Position the lower on the tie rods (6). Lubricate the threads of the tie rods. Screw the tie rod locknuts (8) onto the tie rods. Tighten the locknuts and torque to

50-60 ft-lb (68-81 N•m).

Insert the collars (10) into the coupling nut

(11). Tighten the coupling nut onto the coupling adapter (9) and torque to 90–100 ft-lb (122–135

N•m).

Install the shields (12) by engaging the bottom lips with the groove in the wet-cup cap. Snap the two shields together.

Disconnect the manifold from the lower and plug the ends to prevent fluid contamination.

Loosen the coupling nut (11) and remove the collars (10). Remove the coupling nut from the piston rod (R). Unscrew the locknuts (8) from the tie rods (6). Separate the motor (3) and lower (7).

To repair the lower, see the lower manual.

There are no user-serviceable parts in the motor. Contact your Graco representative for assistance.

Flush and test the pump before reinstalling it in the system. Connect hoses and flush the pump. While it is pressurized, check for smooth operation and leaks. Adjust or repair as necessary before reinstalling in the system.

Reconnect the pump ground wire before operating.

46 334359E

Repair

adapter (16) and tie rods (9) have been disassembled from the motor, to ensure proper alignment of the motor shaft to the piston rod (R).

Screw the tie rods (9) into the motor (1) and torque to 50-60 ft-lb (68-81 N•m).

Screw the coupling adapter (16) into the motor shaft and torque to 90–100 ft-lb (122–135 N•m).

Reassemble the pump to the motor, as explained in

Reassembly, page 46

Torque to 50–60 ft-lb (68–81 N•m).

Torque to 90–100 ft-lb (122–135 N•m).

334359E 47

See

Models, page 3

for an explanation of the pump part number.

48 334359E

34a

34b

34c

34d

34e

1a▲

See

Pump Matrix, page 50

16M130

16W645

16W212

16W211

See

Pump Matrix, page 50

16W214

17B807

108683

15G924

24F251

100101

100133

120351

15H369

184059

184128

16J477

16W645

16E083

24P822

16P911

16P912

111203

24X089

— — —

MOTOR; see motor manual; includes items 1a and 1b

LABEL, warning

OIL, gear, synthetic; ISO 220 silicone-free;

1 quart (0.95 liter); not shown

BRACKET, stand

TUBE, manifold, long

PUMP, displacement; see lower manual

FRAME, stand

CLAMP, sanitary 1.5 in.

NUT, lock, hex

ROD, tie

SHIELD, coupler

SCREW, cap, hex, hd

WASHER, lock, 3/8

GASKET, sanitary

ADAPTER, M22x1.5

NUT, coupling

COLLAR, coupling

CAP, plug

LUBRICANT, gear, bottle

SPACER, open wet cup

MODULE, control kit

CABLE, I.S. CAN, female x female, 3 ft (1 m)

CABLE, I.S. CAN, female x female, 25 ft (8m) purchase separately

WASHER, plain

PRESSURE SENSOR, kit; includes 34a-e

MANIFOLD, 1.5 in. (38 mm), sanitary transducer

SENSOR, pressure, fluid outlet

O-RING

CLAMP, sanitary, 1.5 in. (38 mm)

GASKET, sanitary

▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.

334359E 49

EC4921

EC4931

EC5921

EC5931

EC6921

EC6931

EC4021

EC4031

EC5021

EC5031

EC6021

EC6031

EM0025

EM0026

24F426

24F427

24F434

24F435

24F441

24F442

24F426

24F427

24F434

24F435

24F441

24F442

50 334359E

Technical Specifications

Ref Part

1 24P821

1a▲ 16P265

1b▲ 16P265

1c▲ 16P265

5 24N910

— — —

6 24P823

DISPLAY KIT, control module; includes item 1a; see manual

332013 for approvals information about the bare ADCM module

LABEL, warning,

English

LABEL, warning,

French

LABEL, warning,

Spanish (shipped loose)

CONNECTOR, jumper; includes item 5a

SCREW, cap, socket head; M5 x 40 mm

BRACKET KIT, control module; includes items 6a-6f

Ref Part

— — —

6b — — —

— — —

6e — — —

— — —

11 — — —

— — —

BRACKET, control 1 module

BRACKET, mounting

4 LOCKWASHER, external tooth; M5

WASHER; M5 2

2 SCREW, cap, socket head; M5 x 12 mm

KNOB; M5 x 0.8

HOLDER, tie

STRAP, tie

▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.

Items marked — — — are not available separately.

Cable (25) is shown for reference but is not included in the kit. Order desired length separately. See

Pump Assembly, page 48

334359E 51

Accessories

288117 Pneumatic BPR (20 gpm, 300 psi max fluid pressure, 1–1/4 npt)

288311 Pneumatic BPR (20 gpm, 300 psi max fluid pressure, 1–1/2 npt)

288262

Pneumatic BPR (20 gpm, 300 psi max fluid pressure, 2 in. Tri-Clamp)

16P912

24X089

16V103

24V001

16U729

16M172

16M173

24R086

15V331

25 ft (8m) CAN cable

Pressure Transducer

Transducer Extension Cable

Transducer I/P

Run/Stop Switch

50 ft (15m) Fiber Optic Cable

100 ft (30m) Fiber Optic Cable

Fiber/Serial Converter

Ethernet IP Gateway Assembly

52 334359E

Dimensions

58.00 in. (1473 mm) 17.00 in. (432 mm) 45.50 in. (1156 mm) 19.88 in. (505 mm)

334359E 53

Mounting Hole Patterns

19.88 in. (505 mm)

14.50 in. (368 mm)

16.88 in. (429 mm)

17.00 in. (432 mm)

54 334359E

Models EC4xxx

Models EC5xxx

Models EC6xxx

Maximum continuous cycle rate

Input Voltage/Power, All

EC Models

Power inlet port size

Ambient temperature range

Sound data

Oil capacity (each motor)

Oil specification

Weight

Fluid inlet size

Fluid outlet size

Wetted parts

400 psi

300 psi

210 psi

2.76 MPa, 27.6 bar

2.07 MPa, 20.7 bar

1.45 MPa, 14.5 bar

200–240 Vac, single phase, 50/60 Hz, 5.8 kVA (2.9 kVA per motor)

32–104°F

20 cpm

3/4–14 npt(f)

0–40°C

Less than 70 dB(A)

1.5 quarts 1.4 liters

Graco Part No. 16W645 ISO 220 silicone-free synthetic gear oil

Pump package (motor, 4000cc lower, stand, and tie rods): 440 lb

Pump package (motor, 4000cc lower, stand, and tie rods): 199.6 kg

1.5 in Tri-Clamp

1.5 in. Tri-Clamp

See Lower Pump manual.

334359E 55

To communicate through fiber optics with the E-Flo

DC Control Module, reference the appropriate hardware as shown in manual 332356. That manual indicates various options for connecting fiber optic cables from the control module to the non-hazardous area. The following table lists

Modbus registers available to a PC or PLC located in the non-hazardous area.

Table 3 shows the registers needed for basic operation, monitoring, and alarm control features.

Tables 4 and 5 provide bit definitions as needed for certain registers. Table 6 shows the units and how to convert the register value to a unit value.

Reference the Modbus communication settings selected in

Setup Screen 11, page 36

404100

404101

404102

404103

404104

404105

404106

404107

404108

404109

404110

404111

404112

404113

404114

404115

404200

404201

404202

404203

404204

403102

Pump Status Bits

Actual Pump Speed

Actual Pump Flow Rate

Actual Pump Pressure

Transducer 1 Pressure

Transducer 2 Pressure

Batch Total High Word

Batch Total Low Word

Grand Total High Word

Grand Total Low Word

Maintenance Total High Word

Maintenance Total Low Word

Pump Alarms High Word

Pump Alarms Low Word

Display Alarms High Word

Display Alarms Low Word

Local/Remote Control

Active Profile Number

Pump Control Bitfield

Maintenance Interval High Word

Maintenance Interval Low Word

Display seconds

Read Only

16 Bit

See Table 4 for bit definitions.

Speed units, see Table 6.

Flow units, see Table 6.

Percent pressure, see Table 6.

Pressure units, see Table 6.

Volume units, see Table 6.

Pump cycles, see Table 6.

See Table 4 for bit definitions.

Read / Write 16 Bit

0 = local, 1 = remote/PLC

0 = stopped, 1, 2, 3, 4

See Table 4 for bit definitions.

Pump cycles, see Table 6.

Read Only 16 Bit Use as heartbeat.

56 334359E

Error Code Troubleshooting, page 42

NOTE:

, for a description of each alarm.

11 others

Deviation

Alarm

Deviation

Advisory

Alarm

Deviation

Bit

14 others

Event Type

Alarm

Deviation

Alarm

Deviation

Alarm

Deviation

Alarm

Deviation

Alarm

T3D_

P6D_

ERR_

MND_

V1M_

T2D_

WNC_

CCN_

WMC_

P5D_

WSC_

Event Code

K1D_

K2D_

K4D_

K3D_

P1I_

P2I_

P4I_

P3I_

V1I_

V4I_

CAD_

WXD_

WSD_

Over Temperature

Pressure Transducer Missing

Internal Software Error

Maintenance Count

AC Power Loss

Low Temperature

Version Mismatch

IPC Communication

Internal software error

Multiple Pumps Assigned to Transducer

Zero setting on active profile

Reserved

Event Name

Minimum Speed

Maximum Speed

Minimum Pressure

Maximum Pressure

Under Voltage

Over Voltage

High Pressure 120V

CAN Communication Pump

Board Hardware

Invalid Lower Size

Reserved

334359E 57

Bit

1 others

Event Type

Deviation

Event Code

P6C_

Event Name

Pressure Transducer Missing

Reserved

15 others

Alarm

CAG_

CAC_

Modbus Communication

CAN Communication Display

Reserved

Bit

4 others

Bit

0 others

Meaning

Reads 1 if the pump is trying to move

Reads 1 if the pump is actually moving

Reads 1 if there are any active alarms

Reads 1 if there are any active deviations

Reads 1 if there are any active advisories

Reserved for future use

Meaning

Reads 0 for an active alarm or deviation. Reset to 1 to clear.

Set to 1 to reset the batch total

Set to 1 to reset the maintenance counter

Reserved for future use - only write 0

58 334359E