Graco E-Flo iQ Operation Manual Download Page 55

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Troubleshooting

333587B

Error Codes

Error Location Type

Error Name

Error
Description Cause

Solution

A1__

AMZ

Alarm

Low Current
H_Z_

Heater current
is below the
minimum
allowed value

Fault heater
element

Check heater resistance and resistance to
ground. Replace faulty heater.

A2__

AMZ

Advisory

Low Current
H_Z_

Heater current
is below the
minimum
allowed value

Fault heater
element

Check heater resistance and resistance to
ground. Replace faulty heater.

A3__

AMZ

Alarm

High Current
H_Z_

Heater current
exceeds
maximum
allowed value

Heater element is
defective

Replace heater element.

Heater element is
shorted

Check wiring to the heater element to ensure
no bare wires are touching and that no wires
are shorted to ground.

A4J_

Driver

Alarm

High Motor
Current P_

Motor current
exceeds
maximum
allowed value

Encoder
malfunction

Replace encoders.

Short circuit of
motor wiring

Check wiring to the motor to ensure no bare
wires are touching and that no wires are
shorted to ground.

Motor not able to
rotate

Check that motor shaft rotates freely.

Flow rate is too
large for the motor
to drive the pumps
at the operating
pressure

Reduce the outlet flow rate.

A4N_

Driver

Alarm

High Motor
Current P_

Motor current
exceeds
maximum
allowed value

Encoder
malfunction

Replace encoders.

Short circuit of
motor wiring

Check wiring to the motor to ensure no bare
wires are touching and that no wires are
shorted to ground.

Motor not able to
rotate

Check that motor shaft rotates freely.

Faulty circuit board

Replace motor control circuit board.

A4__

AMZ

Alarm

High Current
H_Z_

Heater current
exceeds
maximum
allowed value

Heater element is
defective

Replace heater element.

Heater element is
shorted

Check wiring to the heater element to ensure
no bare wires are touching and that no wires
are shorted to ground.

A7__

AMZ

Alarm

Unexpected
Current H_Z_

Heat current
has an
unexpected
current flow

Unexpected
Current flow to the
heat element

Fault heater element. Check heater
resistance and resistance to ground.
Replace heater element.

Faulty AMZ; replace AMZ.

Summary of Contents for E-Flo iQ

Page 1: ...scosity fluids For professional use only Not approved for use in explosive atmospheres or hazardous classified locations See page 5 for system component information Important Safety Instructions Read...

Page 2: ...enance 49 Pump Maintenance Screen 1 49 Pump Maintenance Screen 2 50 Diagnostics 51 Pump Diagnostics Screen 51 Heat Diagnostics Screen 51 Pressure Diagnostics Screen 52 Troubleshooting 53 View Errors 5...

Page 3: ...nse Valves Instructions Parts 333586 E Flo iQ Dispense System Installation Parts 3A6321 ADM Token In System Programming 312493 Light Tower Kit Instructions 3A1244 Graco Control Architecture Module 3A6...

Page 4: ...tion Platen Valve Option Size Drum Size Pump Material Seal Material Fieldbus Option EQC E Flo iQ System Revision S Single H Heated Y Yes A 3 in 20 L 5 Gal CS EPDM A Ether Net IP Hose Options for Tande...

Page 5: ...Seventh Digit Check Mate Pump Options Ram Options Platen and Seal Options Interface Options Size Pump Material Heated Ambient Name Size Drum Size Style Platen Size Platen Material Seal Material Wiper...

Page 6: ...at 213 F 400 F 101 C 204 C 05 19M405 10 5 8 in 15 9 mm 10 ft Heated 06 19M406 10 5 8 in 15 9 mm 15 ft Heated 07 19M407 10 5 8 in 15 9 mm 20 ft Heated 08 19M408 10 5 8 in 15 9 mm 25 ft Heated 11 19M411...

Page 7: ...dispense system design the material being pumped and the flow rate the dynamic pressure will not reach the rated working stall pressure of the system Pump Working Stall Pressure Max Dynamic Run Pressu...

Page 8: ...ng any cables and before servicing equipment This equipment must be grounded Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all loc...

Page 9: ...shock Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate...

Page 10: ...g Store hazardous fluid in approved containers and dispose of it according to applicable guidelines BURN HAZARD Equipment surfaces and fluid that is heated can become very hot during operation To avoi...

Page 11: ...e depending on the needs of the system Key A iQ Ram Supply Unit B iQ Dispense Valve C First Hose from Supply System D Second Hose to iQ Dispense Valve E Ram Supply System Fitting to First Hose F First...

Page 12: ...F Supply Hose 1 Fitting to Supply Hose 2 G Supply Hose 2 Fitting to Swivel H Swivel Fitting J Swivel Fitting to Valve K iQ Ram Supply Unit 2 L Tandem Hose 1 M Tandem Hose 2 N Ram Supply Unit 1 Fitting...

Page 13: ...Box Switch AL Platen Lift Rod AM Pump Bleed Valve AN Wet Cup AR Air Line not supplied AS Air Line Drain Valve not supplied AT Air Filter not supplied AU Bleed Type Air Shutoff Valve required not suppl...

Page 14: ...t systems the Disconnect Switch AZ is located on the Power Junction Box AJ On heated systems the Disconnect Switch AZ is located on the Heat Control Box AX Heated systems also have a red and black Pow...

Page 15: ...haust Port with Muffler BD Blowoff Button BE turns air on and off to push the Platen D out of an empty drum Integrated Air Line Accessories See Figure 3 Air Line Drain Valve AS removes condensed water...

Page 16: ...a selection Cancels the pump processes Exits a screen without saving changes CF Enter Select to update a field accept a selection or value acknowledge an event enter a screen and toggle selected items...

Page 17: ...s when the ADM is powered up Five seconds after the E Flo iQ blue token is inserted into the ADM the Graco power up screen switches to the E Flo iQ power up screen This screen remains on while the ADM...

Page 18: ...k the Password screen is displayed If the system is not locked password is set to 0000 iQ Menu Screen 1 is displayed Refer to iQ Menu on page 22 for additional information Press on any Setup screen to...

Page 19: ...Function Alarm See Troubleshooting page 53 for more information Deviation See Troubleshooting page 53 for more information Advisory See Troubleshooting page 53 for more information Target for primary...

Page 20: ...creen Access the Advanced System Setup screens Access the Maintenance function Access the Fieldbus Gateway Setup screens Access the Integration Feedback screens Globalize selection Apply a style setti...

Page 21: ...s into setback and out of setback Enter or exit manual pump movement mode Move to the top Move upward Move downward Move to the bottom Reset Cycle Counter Toggle between lifetime and resettable Calibr...

Page 22: ...on the ADM from any Run screen to go to the iQ Menu screens iQ Menu Screen 1 iQ Menu Screen 2 If you set a password the menu will be displayed with red locks above the menu selections with parameters...

Page 23: ...that it is an E Flo iQ system The Pump shows as Installed The Serial Number should match the serial number printed on the driver ID tag As a backup to the driver serial number the serial number of the...

Page 24: ...ol Modes on page 40 Style Screen 1 Style Definition NOTE When in Local control mode you cannot select Source at this screen but you can still enter Values The Source fields can be changed in Remote co...

Page 25: ...The soft key erases everything you have typed The soft key is the backspace to delete one letter at a time Press the soft key to save the name and exit the keyboard screen Press the soft key to exit t...

Page 26: ...p setup screens This function allows you to configure the operating settings for the pump and drum depending on the mode of operation Pump Screen 1 Pump Settings The following description is the same...

Page 27: ...hange the values and select minus or plus from the drop down menus as appropriate for the calibration 7 Press the soft key to save your changes and exit editing mode Pump Screen 2 Drum Settings Use th...

Page 28: ...ee the System Setup Screen on page 23 Heat Setup Screen 1 NOTE For Tandem systems read this section first then refer to Tandem Heat Setup Screen 1 on page 29 The heat zone number in the first column c...

Page 29: ...d all of Heat Setup Screen 1 starting on page 28 before reading this section The Heat Setup screens for Ram and Tandem are the same in appearance except Tandem has an additional column to the right fo...

Page 30: ...p and platen zones and the zone for the hose that runs from the ram supply unit for P2 to the Ball Valve S on the Tandem Block R since all others are controlled by P1 7 Press the soft key to save your...

Page 31: ...Idle Timeout feature provides the capability to deactivate heat after the pump has not moved for a selected number of hours Enter the number of hours in the box provided 4 The Drum Size at the bottom...

Page 32: ...our system 1 Press the soft key to enter editing mode 2 Select between psi bar and MPa for the Pressure Units 3 Select the Rate between x min and x sec 4 Select the Flow Rate from cc gal US gal UK oz...

Page 33: ...token The latest software is provided on Help graco com Refer to the ADM Token In System Programming manual for a detailed description of this screen See Related Manuals on page 3 Connect Light Tower...

Page 34: ...up button CA on the ADM AF to enable the system 6 At the ADM AF Run screen press the soft key next to the icon to enter editing mode 7 Press the soft key to enter the pump priming mode Two fields appe...

Page 35: ...BC up to raise the Ram AA to its full height 5 Set the Ram Director Valve BC to neutral horizontal position 6 Lubricate the Platen Wiper with grease or another lubricant compatible with the material b...

Page 36: ...steady stream of material with no air comes out of the Pump Bleed Valve AM close the valve 9 Press the soft key to stop the Pump AC Load the Platen Valve and Recirculation Hose NOTE The following ste...

Page 37: ...both Ball Valves S on the Tandem Block R 4 Press the soft key to switch to the currently operating ram supply unit The one currently operating is highlighted in green The Prime icon displays the numb...

Page 38: ...Depressurization Mode on page 40 9 Select to enter or exit dispense valve depressurization mode See Depressurization Mode on page 40 10 Select to enter or exit priming mode See Priming Mode on page 41...

Page 39: ...or exit drum depressurization mode See Depressurization Mode on page 40 10 Select to enter or exit dispense valve depressurization mode See Depressurization Mode on page 40 11 Select to enter or exit...

Page 40: ...pump On Tandem systems press the soft key to switch to Pump 1 or Pump 2 When you press the soft key the Run screen disables other icons on the screen This is indicated by removing the borders of the i...

Page 41: ...hen the priming starts The default is 5 minutes but you can adjust the timer setting to between 1 and 9 minutes See Pump Screen 2 Pump Settings on page 27 5 To manually stop the priming process at any...

Page 42: ...Run screen is available See System Setup Screen on page 23 Use the ADM directional keypad BH to go to the Heat Run screen The Ram Heat Run screen is identical to the Tandem Heat Run screen except for...

Page 43: ...soft key This places all of the zones displayed on the screen to setback and shows the setback temperature in the zone setpoint setback temperature box 3 Press the soft key to take the system out of s...

Page 44: ...the time of the valve opening The Job Log maintains a record of the last 204 jobs that were performed Use the ADM directional keypad BH to scroll through the pages Red text on the Job Log screen indic...

Page 45: ...nts listed on this screen can be downloaded on a USB flash drive To download logs see the Download Procedure on page 64 Errors Log Screen This screen shows the Date Time Error Code and Description of...

Page 46: ...tion Then press the soft key to open the Dispense Valve A allowing the system to depressurize 3 The current pump pressure and current dispense valve pressure show the progress of the depressurization...

Page 47: ...AM open until ready to dispense again 9 If you suspect the dispense valve is clogged or that pressure has not been fully relieved a VERY SLOWLY loosen the hose end coupling to relive pressure gradual...

Page 48: ...and damaging the throat packings See Pump Maintenance Screen 1 on page 49 for information about manually moving the pump using the ADM 5 Always flush the Pump before the fluid dries on the displaceme...

Page 49: ...Use the navigation arrows to move between selections and enter the number using the numeric keypad BJ 3 To reset the Cycles counter use the navigation arrows to move to each one you want to reset and...

Page 50: ...r must be calibrated before operation The histogram represents how hard the driver has been run in its lifetime Each cycle falls between 0 and 100 For example five pump cycles at maximum force would b...

Page 51: ...rate an alarm and shut down the pump The Bus Voltage is the DC voltage of the driver bus The Motor Curren is the active current that is being used by the driver The pump position is shown in inches Th...

Page 52: ...ak countdown timer which is next the column on the right shows the remaining time that the zone will be in heat soak The Line Voltage at the far right of the screen shows the current system voltages c...

Page 53: ...and description The error code alarm bell and active errors will scroll in the status bar Error codes are stored in the error log and displayed on the Error and Troubleshooting screens on the ADM The...

Page 54: ...screen will be displayed Scan the QR code with your smart phone to be sent directly to online troubleshooting for the active error code NOTE For causes and solutions for each error code refer to the...

Page 55: ...wires are touching and that no wires are shorted to ground Motor not able to rotate Check that motor shaft rotates freely Flow rate is too large for the motor to drive the pumps at the operating press...

Page 56: ...n the ADM and driver Yellow LED on driver connector board should be flashing CBD_ Driver Alarm Communication Error P_ Communication lost between pump and ADM No AC power to driver Verify pump is turne...

Page 57: ...ion lost between driver hot and cold boards Software update failure If software updates to the hot or cold driver boards fail before completion then they will not be able to communicate Update softwar...

Page 58: ...ng up state All zones on heat module were successfully placed into warm up No action necessary EBUX ADM Advisory Download to USB Complete Download to USB is complete All requested information has fini...

Page 59: ...ch desired rate Clog in fluid supply system Check hose and other components in fluid supply system for clogs No air pressure to solenoid valves Turn on air to solenoid valves No material supply Replac...

Page 60: ...he setup screen MG2_ Pump Advisory Low Filter Pressure P_ Low filter pressure drop detected The filter has an opening in it Replace the fluid filter MG3_ Pump Advisory High Filter Pressure P_ High fil...

Page 61: ...ermistor is not connected or faulty Verify motor temperature thermistor is installed and or connected correctly Replace if necessary T2__ AMZ Advisory LowTemperature H_Z_ Temperature of the zone is be...

Page 62: ...heck fuse on the AMZ that the error element is connected to Check that electrical connector on the heated hose is plugged into the AMZ Defective heater rods in element Replace V1M_ Driver Alarm Low Vo...

Page 63: ...are Mismatch P_ Software mismatch detected in the motor control board Hot board and cold board have different software versions Update the driver control board software to the latest available on help...

Page 64: ...TAxxxx folder 10 Open the DATAxxxx folder labeled with the highest number The highest number indicates the most recent data download 11 Open the log file Log files open in Microsoft Excel by default a...

Page 65: ...automation status bits that are used by Graco to further diagnose the status of the system System Configuration Settings The system configuration settings file name is SETTINGS TXT and is stored in th...

Page 66: ...ove rows to the file Do not change the order of the rows Upload Procedure Use this procedure to install a system configuration file and or a custom language file 1 If necessary follow the Download Pro...

Page 67: ...2 24 VDC Digital Input 4V is ON 1 V is OFF Style Enable When the digital input is ON the pump will start a job and begin pre charge if active When the digital input is OFF the pump will not be running...

Page 68: ...to the E Flo iQ Supply System Installation Parts Manual for additional information about Electric Driver Connections See Related Manuals on page 3 FIG 9 Electric Driver Connections Connector 3 Connec...

Page 69: ...heat Notes Can be enabled at the same time Can only be used through the fieldbus and must be used to operate the system 3UH FKDUJH ZLOO RQO EH DFWLYH ZKHQ WKHUH LV D VHW SRLQW VWRUHG LQ WKH GLVSOD RU...

Page 70: ...e Remote Start Request C4 5 6W OH QDEOH Prechargring R 6LJQDO DV UHTXLUHG Dispense Complete C4 1 Notes DQ EH HQDEOHG DW WKH VDPH WLPH LI WKHUH LV QR SUHFKDUJH The dispense complete is optional This bi...

Page 71: ...p correctly see the Gateway Map table NOTE If the PLC connection parameters are not setup correctly the connection between the E Flo iQ and PLC will not be made Available Internal Data Unless stated o...

Page 72: ...Boolean 7 17 Platen Depressurization Active Boolean 0 2 18 Auto Depressurization Active Boolean 1 19 Auto Depressurization Happened Boolean 2 20 Pump is trying to move Boolean 3 21 Pump is actually mo...

Page 73: ...rol Boolean 1 50 System Active Boolean 2 51 PLC Lockout Control Active Boolean 3 52 No Alarms Active Boolean 4 53 No Deviations Active Boolean 5 54 No Advisory Active Boolean 6 55 System Ready to disp...

Page 74: ...an 6 91 Heat is in Setback Mode Boolean 7 92 Heat is Off Boolean 0 55 93 No Heat Module Alarms Active Boolean 1 94 No Heat Module Deviations Active Boolean 2 95 No Heat Module Advisories Active Boolea...

Page 75: ...Alarms Active Boolean 4 135 No Heat Zone s Deviations Active Boolean 5 136 No Heat Zone s Advisories Active Boolean 6 137 Heat Idle Timeout Happened Boolean 7 138 Reserved Bit 1 Boolean 0 68 139 Reser...

Page 76: ...uest Boolean 2 13 Acknowledge Clear Errors both pumps Boolean 3 14 Reserved Bit 1 Boolean 4 15 Reserved Bit 2 Boolean 5 16 Reserved Bit 3 Boolean 6 17 Reserved Bit 4 Boolean 7 18 Desired Active Style...

Page 77: ...24 64 System Heat Disable Request Boolean 1 65 Heat PLC Lockout Control Boolean 2 66 Heat On Request Boolean 3 67 Heat Off Request Boolean 4 68 Heat Setback Request Boolean 5 69 Acknowledge Clear Heat...

Page 78: ...Number 0 FIRST DOWN 1 UP 2 DOWN 3 TOP CHANGEOVER 4 BOT CHANGEOVER 14 Average Motor Current x xxx Amps 15 Motor Temperature xx deg C 16 IGBT Board Temperature xx deg C 17 Bus Voltage xxx xx Volts E Flo...

Page 79: ...Zone At Temperature 4 Heat Zone is Heat Soaking 5 Heat Zone is in Setback 6 Heat Zone has an Error x004 Zone x Actual Temperature xx deg C x005 Zone x Actual Current Usage xx xxx A x006 Zone x Actual...

Page 80: ...Display Comm Error P_ 21 P6V_ Valve Pressure Sensor P_ 22 WSN_ Invalided Style P_ 23 WNC_ iQ Software Not Selected P_ 24 WMH_ Control Board Off P_ 25 Reserved 26 Reserved 27 Reserved 28 Reserved 29 Re...

Page 81: ...4 MG3_ High Filter Pressure P_ 5 MLD_ Maint Due Platen Valve P_ 6 MED_ Maint Due Dispense Valve P_ 7 Reserved 8 Reserved 9 Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Rese...

Page 82: ...d 22 Reserved 23 Reserved 24 Reserved 25 Reserved 26 Reserved 27 Reserved 28 Reserved 29 Reserved 30 Reserved 31 Reserved AMZ Active Module Deviation Bit Number Deviation Code Deviation Name 0 V2H_ Lo...

Page 83: ...O Daughter Board Active Module Alarms Bit Number Alarm Code Alarm Name 0 TA1_ Heat Zone Offline Z1 H_ 1 TA2_ Heat Zone Offline Z2 H_ 2 TA3_ Heat Zone Offline Z3 H_ 3 TA4_ Heat Zone Offline Z4 H_ 4 TA...

Page 84: ...ved 23 Reserved 24 Reserved 25 Reserved 26 Reserved 27 Reserved 28 Reserved 29 Reserved 30 Reserved 31 Reserved I O Daughter Board Active Module Advisories Bit Number Advisory Code Advisory Name 0 Res...

Page 85: ...Reserved 17 Reserved 18 Reserved 19 Reserved 20 Reserved 21 Reserved 22 Reserved 23 Reserved 24 Reserved 25 Reserved 26 Reserved 27 Reserved 28 Reserved 29 Reserved 30 Reserved 31 Reserved AMZ Active...

Page 86: ...H_Z_ 3 Reserved 4 A3__ High Current H_Z_ 5 A2__ Low Current H_Z_ 6 Reserved 7 Reserved 8 Reserved 9 Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Reserved 16 Reserved 17 Rese...

Page 87: ...ressure Target integer Prime Flow Target integer Prime Inactive Pump Request uses the inactive pump on tandem and active on single ram Timeout Can all be enabled at once Depressurize Automation Inputs...

Page 88: ...s Heart Beat 1Hz System is Active No Alarms Active XWRPDWLRQ RQWURO 5HDG Automation Outputs E Flo iQ Inputs System Enable Request Note 7KH V VWHP PXVW EH LQ UHPRWH PRGH Ack Clear Error Automation Inpu...

Page 89: ...el Pump 1 example Heart Beat 1Hz Tandem Active Pump Automation Outputs E Flo iQ Inputs Cross Over Request Pump 1 Active Pump 2 Active Data Exchange Automation Inputs E Flo iQ Outputs Heart Beat 1Hz Da...

Page 90: ...s System Heat Enable Request System Heat Disable Request Heat PLC Lockout Control Other Automation Outputs Instances and Heat Module Data Exchanged Command Desired Value Notes System Heat Enabled Requ...

Page 91: ...ors are not successfully resolved fixed the bit will reminder high once the system has successfully seen that the error has been resolved the bit will go low Heat Zone Ack Clear Error Automation Input...

Page 92: ...iQ Outputs Heart Beat 1Hz Heat ModuleData Exchange Active Command Heat Module Data Exchange Active Command Value 5Hz Automation Outputs E Flo iQ Inputs Heat Module Data Exchange command integer Heat P...

Page 93: ...tate TI11814A NS MS Link State Description Comments Off Not initialized No power or module in SETUP or NW_INIT state Green Normal operation Diagnostic event s present Flashing Green Initialized diagno...

Page 94: ...in Idle state Red Major fault EXCEPTION state FATAL error etc Flashing Red Recoverable fault s State Description Off No link no activity Green Link established Flashing Green Activity TI11814A NS MS...

Page 95: ...ff No power or not initialized Green Initialized Flashing Green Initialized diagnostic event s present Red Exception error Pin Signal Description 1 2 3 B Line Positive RxD TxD RS485 level 4 RTS Reques...

Page 96: ...Some screens are informational only For those that can be edited press the soft key to enter editing mode Use the Directional Keypad CH and Numeric Keypad CJ to make changes PROFINET PROFINET Screen 1...

Page 97: ...You can view the Hardware Revision System Serial number and data map identification information at this screen PROFIBUS PROFIBUS Screen 1 This screen allows you to set the Device Address Install Date...

Page 98: ...Integration 98 333587B DeviceNet At this screen you can set the Device Address and Baud Rate and view the Hardware Revision System Serial number and data map identification information...

Page 99: ...Flo iQ The numbers to the right of each signal represent the connector and pin number on the E Flo iQ driver See Connector Identification on page 68 The colors to the left of the connector pin number...

Page 100: ...d ductile iron EPDM PTFE coated aluminum 6061 aluminum Buna Viton Zinc plated steel 316 stainless steel 17 4 stainless steel 25R099 5 gal 20 L Electroless nickel plated ductile iron EPDM PTFE coated a...

Page 101: ...of a product s useful life recycle it in a responsible manner For additional information refer to the E Flo iQ Dispense System Installation Parts manual See Related Manuals on page 3 California Propos...

Page 102: ...e at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LI...

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