Page 1 ADAC 1000 Deaerator Control Operation Manual 750-386 05/2017...
Page 2 DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL. DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL. FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH.
Page 3: Table Of Contents
CONTENTS Chapter 1 - General Introduction ......... . 1-2 Single Tank System Description .
Page 4 Part List..........6-2 APPENDIX A - Variable Frequency Drive Parameters APPENDIX B - ADAC 1000 ProtoNode Tags APPENDIX C - Loading a PLC Program...
Page 5 ADAC Software ........1-6 www.cleaverbrooks.com...
Page 6: Chapter 1 - General
In addition to installation on new Deaerators and Surge tanks, the ADAC 1000 can be added as a retrofit to existing tanks. Call your local authorized Cleaver-Brooks representative for details. 1.2-Single Tank System Description...
Page 7 • Tank Discrete Level Switches Option 3 • VFD Pump 4-5 Option 4 • User Configured Analog Inputs • Tray Temp/Pressure Analog Inputs for Tray Deaerators Note: Each ADAC 1000 programming option requires the corresponding hardware (drives, valves, transmitters, switches, etc.) Part No. 750-386...
Page 8: Two Tank System Description
Chapter 1 — General 1.3-Two Tank System Description Two Tank systems can control up to 4 boiler feed pumps and 3 transfer pumps (6 pumps total), all of which can be run by contactors, combination starters, soft starters, or Variable Frequency Drives.
Page 9 Chapter 1 — General Communication options include OPC compliant Ethernet IP to Boiler master panel or customer BAS. PLC based control system for a two tank starts with and includes a base unit consisting of the processor and embedded I/O, power supply, I/O cards, 7"...
Page 10: Specifications
Chapter 1 — General Note: Each ADAC 1000 programming option requires the corresponding hardware (drives, valves, transmitters, switches, etc.) 1.4-Specifications Power Power Supply Voltage 120 VAC (102 VAC - 132 VAC) Power Supply Frequency 50 or 60 Hz Maximum Total Connected Load...
Page 11: Chapter 2 - System Components
Optional Accessories ........2-9 www.cleaverbrooks.com...
Page 12: Components
Chapter 2 — System Components 2.1-Components The ADAC control system consists primarily of a Programmable Controller (PLC), touch screen Human Machine Interface (HMI), 24VDC power supplies, stack light, and various relays. Optional components could include an EtherNet switch. The ADAC controller is factory pre-programmed to work with most Cleaver-Brooks deaerator and surge tank systems, yet allows easy configuration for specific options.
Page 13 Pump Running (yes/no) Analog signals can assume almost infinite values within the fixed analog input/ output current range of 4-20 mA. The ADAC 1000 PLC converts this current value to a range in engineering units. Example: Steam Header Pressure (0-150 PSI) Note: The PLC expects each device to be in a specific slot location.
Page 14 Chapter 2 — System Components 6. Slot 3 - Embedded High Speed Counter (not used) Standard IO can accommodate: Standard: 1-5 Pumps - without VFD Common Header with Header Pressure Control 2 MUV's - One Primary - One Secondary Optional Cards 7.
Page 15 Chapter 2 — System Components Optional Cards 8. Slot 5 - Digital Inputs 24VDC 9. Slot 6 - Analog Outputs 8 channel 10. Slot 7 - Digital Inputs 24VDC For specific input/output assignments see tables in Chapter 5. 2.1.2 - Operator Interface A 7”...
Page 16 Chapter 2 — System Components • Email or texting of ADAC alarms to plant or service personnel Ethernet/IP is also used for certain control functions. With a C-B Master Panel, individual boiler controllers can be networked with the ADAC, providing a single BAS interface for multiple boilers and one ADAC system.
Page 17: Control Panel
Chapter 2 — System Components controller. It transmits a 4-20mA process variable signal to the controller for the purpose of displaying pressure inside the tank or to provide a process value for optional PRV control. • Hot Water Temperature Transmitter (Fig. 2-5); one per tank. This transmitter provides a sensor input to the ADAC controller.
Page 18 Chapter 2 — System Components Figure 2-8. DIN rail latches Figure 2-9. Expansion I/O Module locking levers The module locking levers should all be securely seated to the left. Panel and Field Wiring Terminations Check that all factory wiring connections are tight and that field wiring terminations are completed and secure.
Page 19: Optional Accessories
Chapter 2 — System Components 2.3-Optional Accessories 2.3.1 - Sensors • Water Level, 4-20mA signal, one per tank (Fig. 2-10). •Header Pressure Transmitter, 4-20 mA signal (used for pump lead/ lag and alternation), one per tank for common headers (Fig. 2-11). Required on common headers;...
Page 20 Chapter 2 — System Components NOTE: The float must be installed before the transmitter or level indicator will work. The float is laser etched with the word “TOP” and an arrow indicating the direction the float must be inserted into the chamber.
Page 21 Chapter 2 — System Components Setting Zero and Span - E&H Transmitter Follow steps 1-5 above. 6. Fill deaerator with water to the bottom of the gauge glass and select EMPTY CALIB. parameter. Enter the level value (0 eng. units) and con- firm the value to assign the pressure value present to the lower level value.
Page 22 Chapter 2 — System Components 2-12 Part No. 750-386...
Page 23 System Information ........3-49 Display Configuration ........3-50 www.cleaverbrooks.com...
Page 24: Chapter 3 - Commissioning
Chapter 3 — Commissioning Note: Certain screen layouts may differ between single tank and two tank systems. 3.1-Main Menu On system power-up, the Main Menu is displayed. This screen provides pushbutton access to the various Operator, Configuration, and Alarm screens. Figure 3-1 Main Menu 3.2-Begin System Configuration If the system has not been configured, the <System Config...
Page 25 Chapter 3 — Commissioning Figure 3-2 Numeric keypad The ADAC 1000 uses three levels of password access: Operator, Service, and Factory. Passwords are available from your Cleaver- Brooks representative. Figure 3-3 Login prompt Part No. 750-386...
Page 26: System Configuration Screen 1 - Single Tank
Chapter 3 — Commissioning The first item to configure is the number of pumps (single tank systems) or boiler feed pumps (dual tank systems). Press <Number of [Boiler Feed] Pumps> for the numeric input keypad. Enter the appropriate number of pumps and press the ENTER key. After entering the number of pumps, the rest of the configuration options will appear.
Page 27 Chapter 3 — Commissioning Figure 3-5 System config. warning 3.3.1 - Common Header A header pressure sensor is required for common header systems. Pump control method can be either contactor or VFD. 3.3.2 - One Pump per Boiler Header pressure sensor not required; uses a discrete “Water Required”...
Page 28: System Configuration Screen 1 - Dual Tank
Chapter 3 — Commissioning Variable Frequency Drive • 4-20mA PLC analog output signal to command pump speed • NO analog speed feedback signal • VFD bypass available Tray Sensors (monitor only) & alarm • Temperature • Pressure Makeup Water Valves •...
Page 29: System Configuration Screen 2 - Single Tank
Chapter 3 — Commissioning Other selections for dual tank systems are: Makeup Water Valves • 2 Valves Maximum per Tank • 3 Valves Maximum per System To provide PID controlled makeup water to maintain tank level. Reverse acting selection available. Direct Acting: 4mA = valve closed;...
Page 30: System Configuration Screen 2 - Dual Tank
Chapter 3 — Commissioning Recirculation Valve • Discrete Output Valve Control. • Recirc valve open/close signal based on header pressure. Auxiliary Analog Inputs • 4 user configurable analog inputs. • 1 input required if tray temperature is monitored. • 1 input required if tray pressure is monitored. Digital Input Present –...
Page 31: Transfer Pumps - Dual Tank Systems
Chapter 3 — Commissioning Chemical Feed • Discrete Pump Running Output Signal to Chemical Feed System. Recirculation Valve • Discrete Output Valve Control. • Based on Header Pressure. DA Bypass • Bypass DA during tank inspection or maintenance. • Boiler Feed Pumps draw water directly from Surge Tank. DA Bypass Alarm Disable •...
Page 32: System Configuration Screen 3
Chapter 3 — Commissioning 3.8-System Configuration Screen 3 Figure 3-9 System Configuration 3 Transfer Pump Control • Contactor or VFD. • VFD Bypass Available. Transfer Pump Proving • Verify pump operation by use of flow meter, pressure switch, or current toroid. •...
Page 33: System Configuration Summary
Chapter 3 — Commissioning • Requires Communication Watchdog. Makeup Water Valves • 2 Valves maximum per tank • 3 Valves maximum per system • To provide PID controlled primary and secondary makeup water to tank(s). • Reverse acting selection available Bias DA Primary MUV •...
Page 34 Chapter 3 — Commissioning The button is visible ONLY if Pumps have been configured to a non- zero value. Configuration is required if transmitter span value equals zero. Figure 3-11 System Config complete 3.10.1 - Analog Input Config Select Screen Figure 3-12 Analog Input Configuration select “Required”...
Page 35 Chapter 3 — Commissioning Figure 3-13 Configure Selected Input (Header Pressure) The following should be configured: Transmitter Span • Corresponds to 20ma Signal. • Entry cannot be greater than 99999. • Entry cannot be less than Zero value. Transmitter Zero •...
Page 36 Chapter 3 — Commissioning 3.10.3 - Tank Level Figure 3-14 Configure Tank Level Tank Level High Alarm • Entry cannot be greater than Span value. • Entry Cannot be less than Low Alarm value. Tank Level Low Alarm • Entry cannot be greater than High Alarm value. •...
Page 37: Analog Input View
Chapter 3 — Commissioning 3.11-Analog Input View Figure 3-15 Analog Input View - single tank Transmitter zero, span, midpoint and current reading are displayed for all configured inputs. If alarms are enabled for the input, the alarm limits will also be displayed. A trending screen is available for each analog input.
Page 38: Pump Configuration
Chapter 3 — Commissioning • The Lag Pump start time and start pressure/VFD% can be adjusted to achieve set point more quickly. Screen displays 20 minute intervals at a time. Figure 3-17 Analog Input Trend 3.13-Pump Configuration Pump configuration should be performed after analog input configuration is complete.
Page 39 Chapter 3 — Commissioning Figure 3-18 Pump Configuration (not logged in) 3.13.1 - Pump Rotation Pump rotation is only available on common header applications. This feature allows for automatic pump Lead Lag order rotation based on pump rotation elapsed time. Upon pump rotation: •...
Page 40 Chapter 3 — Commissioning Figure 3-19 Pump Configuration (after login) 3.13.2 - Pump Auto Restart This feature allows for Automatic Pump Restart after an Analog Low Water Cutoff Alarm. • Requires tank level transmitter. • Pump Lead Lag must be enabled to auto restart pumps. •...
Page 41 Chapter 3 — Commissioning 3.13.3 - Pump Lead Lag with VFD Only available on common header applications. Allows for automatic start and stop of Lag pumps based on VFD output%. The Lead pump always runs. Lag Start VFD% Speed • If the VFD output% rises above the Lag Start VFD% Speed for the Lag Start Delay Time the next Lag Pump will be commanded to start.
Page 42: Pump Control
Chapter 3 — Commissioning • If the user enters an invalid Lead Lag order. • 1 pump per boiler applications. 3.13.5 - One Pump per Boiler Only the Pump Auto Restart feature is available. Transfer Pump Configuration is set up identically to feed pump configuration, with the exception that transfer pumps cannot be configured as One Pump per Boiler.
Page 43 Chapter 3 — Commissioning Pump Start/Stop • When Lead Lag is Enabled status indication only. Running - Stopped • When Lead Lag is Disabled push button becomes available to manually start/stop pump. Pump Status • Off = Pump not running •...
Page 44 Chapter 3 — Commissioning 3.14.3 - Pump Control - Pump Lead Lag Invalid Pump Lead Lag Invalid mode is indicated on the HMI when an invalid pump lead lag sequence is entered. • Manually changing the lead lag order will momentarily render the lead lag sequence invalid and will disable pump lead lag •...
Page 45 Chapter 3 — Commissioning 3.14.5 - Pump Control - Lead Lag Enabled (Transfer Pump, Dual Tank systems), VFD Selected Pump Operating Mode Hand – Off – Auto - VFD Bypass Pump Start/Stop • When Lead Lag is Enabled status indication only. Running - Stopped •...
Page 46 Chapter 3 — Commissioning 3.14.6 - Pump Control - Lead Lag Enabled, NO VFD Selected Pump Operating Mode Hand – Off – Auto Pump Start/Stop • When Lead Lag is Enabled status indication only. Running - Stopped • When Lead Lag is Disabled push button becomes available to manually start/stop pump.
Page 47: Pump Vfd Control
Chapter 3 — Commissioning 3.15-Pump VFD Control The ADAC 1000 supports PowerFlex 400, 700, 70, and 753 drives. Other drives are not recommended. Pump control with VFD is available on the boiler feed pumps and on the transfer pumps. VFD not available for feed pumps on One Pump per Boiler applications.
Page 48 Chapter 3 — Commissioning When Output% is between 0-16% the Pump Speed will be 16% and will increase linearly with the control output when the control output is greater than 16% An operator level password is required to adjust Header Pressure Setpoint.
Page 49 3.15.3 - Feed Pump VFD Control – Remote Set Point by comms Figure 3-23 Remote SP by Comms The ADAC 1000 can receive a remote feedwater header pressure setpoint signal by means of Ethernet communication. To use this feature select <Remote> setpoint mode by HMI pushbutton.
Page 50 Chapter 3 — Commissioning Figure 3-24 VFD Trend 3.15.5 - Pump VFD Tuning and Trend PID adjustment requires operator level password. Use arrow keys to move along the time axis. Trend Header Pressure vs. Set Point. Trend Control Output. Screen displays 20 minutes at a time. Figure 3-25 Pump VFD Tune &...
Page 51: Primary Makeup Valve Control
Chapter 3 — Commissioning 3.16-Primary Makeup Valve Control Single Tank - One primary makeup valve is allowed. Dual Tank - Two primary makeup valves are allowed, one per tank. In Auto mode the control output is modulated based on tank water level.
Page 52 Chapter 3 — Commissioning 3.16.1 - Primary Makeup Valve Control Output Trend Figure 3-27 Primary MUV Control Output Trend 3.16.2 - Primary Makeup Valve Tuning and Trend Figure 3-28 Primary MUV Tuning & Trend PID adjustment requires operator level password. Use arrow keys to move along the time axis.
Page 53: Primary Makeup Valve Bias
Chapter 3 — Commissioning 3.16.3 - Primary Makeup Valve Help Screen A help screen is available for primary makeup valve control. Press <Pri Makeup Valve Help> from the PMUV Control Screen to access. Figure 3-29 Primary MUV Help 3.17-DA Primary Makeup Valve Bias Figure 3-30 DA PMUV Bias This feature is only available on dual tank systems.
Page 54 Chapter 3 — Commissioning The DA Primary Makeup Valve (Transfer Valve) may be biased toward the Full Closed position if the water level in the Surge Tank becomes too low. Biasing the transfer valve will help prevent the Surge Tank water level from reaching a Low Water Cutoff level, disabling the Transfer Pumps.
Page 55: Secondary Makeup Valve Control
Chapter 3 — Commissioning 3.18-Secondary Makeup Valve Control Single Tank - One secondary makeup valve is allowed. Dual Tank - One secondary makeup valve is allowed and can be for either the DA or surge tank. Secondary makeup valve control has the same features as the primary makeup valve with the exception of valve biasing.
Page 56: Overflow Valve Control
Chapter 3 — Commissioning 3.20-Overflow Valve Control Available on single tank applications. Only available on the DA tank in dual tank applications. Only available if the Steam PRV Valve option is NOT selected. In Auto mode the control output modulates linearly based on tank level.
Page 57: Chemical Feed Control
Chapter 3 — Commissioning 3.21-Chemical Feed Control Available on single tank applications. Available on both DA and Surge Tank on dual tank applications. Discrete Output for On/Off control. DA uses the Feed Pump Running chemical feed output for control. Surge uses Transfer Pump Running chemical feed output for control. The Chemical Feed Relay output will energize anytime a pump is running and the Start Delay has expired.
Page 58 Chapter 3 — Commissioning 3.21.1 - Recirculation Valve Control Recirculation valve control is available on single tank applications. Only available on DA in dual tank applications. Discrete Output for On/off control. The Recirculation Valve will open when Header Pressure exceeds the Valve Open Pressure.
Page 59: Bypass
Chapter 3 — Commissioning 3.22-DA Bypass For dual tank systems only; this feature allows the DA to be bypassed for maintenance or inspection. In DA Bypass mode the boiler feed pumps draw water directly from the surge tank. A Normal – Bypass selector switch and corresponding Low Water Cutoff wiring of the control panel is required for the DA Bypass function to operate correctly.
Page 60 Chapter 3 — Commissioning Figure 3-36 DA Bypass - No Surge MUV The DA Secondary MUV must be configured in both Normal and Bypass Mode Pressing a “grayed out” push button will display an informational message. In DA Bypass mode, no matter the makeup valve configuration the DA primary makeup valve control output is snapped to zero and the PID is snapped to manual mode.
Page 61 Chapter 3 — Commissioning Upon entering Normal mode, the makeup valve is automatically put into auto and will modulate based on tank level. 3.22.2 - DA Bypass - With Surge Primary MUV In this mode no additional control setup is required since the Surge Primary Makeup Valve will provide makeup water to the Surge Tank in both modes.
Page 62 Chapter 3 — Commissioning 3.22.3 - DA Bypass Typical Wiring Figure 3-38 DA Bypass Wiring 1 of 2 Figure 3-39 DA Bypass Wiring 2 of 2 3-40 Part No. 750-386...
Page 63: Auxiliary Analog Inputs
Chapter 3 — Commissioning 3.23-Auxiliary Analog Inputs Single and Dual Tank Systems can have up to 4 Auxiliary Analog inputs. • This feature is standard on dual tank applications, uses I:4.3 – I:4.6 • Optional on single tank applications, uses I:7.0 –...
Page 64 Chapter 3 — Commissioning An operator level password is required to modify any values. Configurable values are: Name Enter any name – 20 characters maximum Units Enter any unit – 8 characters maximum Span User defined 20ma scaling on analog input device. Zero entry to 999999 entry limits Zero User defined 4ma scaling on analog input device.
Page 65: Lead Lag Order By Communications
Chapter 3 — Commissioning 3.23.1 - Auxiliary Analog Input View To view the status of the auxiliary analog inputs, press <Auxiliary Analog Input View> from the Main screen. Alarm levels displayed only if alarms are enabled. Can trend all analog inputs. If span value = 0, input is NOT configured High and Low...
Page 66: Plc Ethernet Configuration
Chapter 3 — Commissioning E t h e r n e t c o m m u n i c a t i o n i n t e g r i t y i s d e t e r m i n e d b y a communication heartbeat signal between the Cleaver Brooks ADAC PLC and the Building Management System.
Page 67 Chapter 3 — Commissioning Figure 3-44 PLC Ethernet Configuration A Service Level password is required to modify the Ethernet Configuration. Enter new Ethernet Configuration under “Set New PLC Ethernet Configuration” When new Configuration is entered press “Configure PLC Ethernet”. A pop-up will appear: NOTE: The PLC must be in REM and the RUN LED must be GREEN to configure the Ethernet port.
Page 68: Text/Email
Chapter 3 — Commissioning 3.26-Text/Email SMTP* Server Configuration is required in order to use text and email functions. When configuration is complete, email or text messages can be sent directly from the PV+. New systems shipped from Cleaver Brooks will have the latest revisions of firmware.
Page 69: Plc Input/Output Status
Chapter 3 — Commissioning 3.27-PLC Input/Output Status This screen shows On/Off status of digital I/O, and for Analog I/O the following values: Analog Input Raw Analog signal in mA or volts that is the actual value on the PLC analog input module. Analog Input Value Analog Signal scaled value.
Page 70: Contact Information
Chapter 3 — Commissioning Figure 3-47 Update Date and Time 3.29-Contact Information Requires Operator Level Password. Figure 3-48 Contact Information 3-48 Part No. 750-386...
Page 71: System Information
Chapter 3 — Commissioning 3.30-System Information Displays customer and contact names and s y s t e m I D , s o f t w a r e , a n d n e t w o r k information Figure 3-49 System Information Part No.
Page 72: Display Configuration
Chapter 3 — Commissioning 3.31-Display Configuration Most of the PanelView parameters are preset and should not be changed. A few commonly used PV configuration features are described here. 3.31.1 - Date and Time In addition to the procedure described in 3.28 above, the system date and time can be changed using PV configuration.
Page 73 Chapter 3 — Commissioning Select the value to change. Enter the desired value in the numeric keypad and press return. When finished press the <EXIT> button. 3.31.2 - Screen Saver The display has a screen saver feature. To enable and to adjust settings, go to Terminal Settings>Display>Screen Saver.
Page 74 Chapter 3 — Commissioning 2.Press the Source button to select the storage location of the application file you want to load. • Internal Storage - the internal CompactFlash in the terminal. • External Storage 1 - the external SD card loaded in the card slot of the terminal.
Page 75 PLC Status ......... . 4-11 www.cleaverbrooks.com...
Page 76: Chapter 4 - Operation
Chapter 4 — Operation 4.1-System Monitoring and Operation 4.1.1 - Screen Select On system power-up, the Main Menu will be displayed. This screen allows access to all of the primary control, monitoring, and configuration sections of the ADAC system. Figure 4-1 Main Menu Graphic displays of the DA system are accessed by pressing <Tank Overview>...
Page 77 Chapter 4 — Operation • DA Header Pressure • DA Tank Temperature • DA Tank Level • DA Tank Pressure • Lead-Lag status (Lead, Lag1, Lag2, etc.) for each of the Feed Pumps • OFF/ON/FAULT status for each of the Feed Pumps •...
Page 78 Chapter 4 — Operation 4.1.4 - Duo Tank Overview If a DUO TANK system has been selected in the Option Select screen, a <Tank Overview> button will be available on the Main Menu for access to the Duo Tank Overview screen. Features are similar to the DA/Surge Overview screens.
Page 79 Chapter 4 — Operation • Status of the optional Flow Switches – OPEN/CLOSED • Selector Switch Position HAND/OFF/AUTO • OFF/ON/FAULT status for each of the Feed Pumps • Lead-Lag status (Lead, Lag1, Lag2, etc.) for each of the Feed Pumps •...
Page 80: Remote Monitoring
Chapter 4 — Operation 4.1.6 - Transfer Pump Control Information and controls on this screen are similar to Feed Pump Control above. Figure 4-6 Transfer Pump Control Screen 4.2-Remote Monitoring The PanelView Plus HMI provides Web Server functionality, allowing for easy access to plant floor HMI applications. There is no need to install any additional Rockwell software on the browser computer.
Page 81 Chapter 4 — Operation On the alarm screen choose between <Active Alarms>, showing only those alarms currently active, or <Alarm History> for a record of all the most recent alarms (up to the last 200). When an alarm occurs, the alarm relay will de-energize, sounding the alarm bell/horn.
Page 82: Troubleshooting
Chapter 4 — Operation 4.4-Troubleshooting Fault Text System Failure Condition Recommended Troubleshooting Feed Pump # Run Pump has not started or Feed Pump 1: Pump Start Output 1. Verify Pump I/O is energizing and deenergizing correctly Fault stopped in required time O:2/0 is energized and Pump On and within 5 seconds.
Page 83 Chapter 4 — Operation DA Tank Level Low Tank Level has reached Low Water Cutoff Level Switch 1. Verify Tank Level Switch Wiring and proper mechanical Water Cutoff the Low Water Cutoff has deenergized the tank low low operation. When PLC input is deenergized alarm will be (Digital Input) Level Switch.
Page 84 Chapter 4 — Operation DA Tank Level Tank Level Sensor Failure. Analog input is outside of range. 1. Verify Analog Input Wiring. Sensor Failure Range > 3.3 ma 2. L24ER Embedded I/O requires a jumper between I in Range < 20.5ma 0+ and V in 0+ for slot 2 Analog.
Page 85: Plc Status
Chapter 4 — Operation Auxiliary Analog Input Auxiliary Analog Input too Analog Input is above High Alarm 1. Verify Auxiliary Analog Input High Setpoint for Time. 2. Adjust Alarm Settings. High 3. Alarms may be disabled by setting Alarm Time = 0 Seconds.
Page 86 Chapter 4 — Operation Table 4-1. PLC Status LEDs (Continued) No power is applied. Green The controller is OK. Flashing green The controller is storing a project to or loading a project from the SD card. The controller detected a nonrecoverable major fault and cleared the project from memory. Flashing red One of the following: •...
Page 87: Chapter 5 - Input/Output Lists
Two Tank PLC I/O Layout ....... . . 5-4 www.cleaverbrooks.com...
Page 88: Single Tank Plc I/O Layout
Chapter 5 — Input/Output Lists 5.1-Single Tank PLC I/O Layout 5.1.1 - ADAC Single Tank STANDARD I/O Slot 1 - Embedded Digital Inputs - 24VDC Slot 1 - Embedded Digital Outputs Address Name Address Name I1/0 Pump 1 On / VFD Run Contact O1/0 Pump 1 Start (PR1) / VFD Run I1/1...
Page 89 Chapter 5 — Input/Output Lists 5.1.2 - ADAC Single Tank OPTIONAL I/O Option 1: VFD Pump 1-3 PRV or Overflow Valve Slot 4 - Analog Outputs - 1769-OF4 Address Name O4/0 Pump 1 VFD Speed Control O4/1 Pump 2 VFD Speed Control O4/2 Pump 3 VFD Speed Control O4/3...
Page 90: Two Tank Plc I/O Layout
Chapter 5 — Input/Output Lists 5.2-Two Tank PLC I/O Layout 5.2.1 - ADAC Two Tank STANDARD I/O Slot 1 - Embedded Digital Inputs - 24VDC Slot 1 - Embedded Digital Outputs Address Name Address Name I1/0 Feed Pump 1 On / VFD Run Contact O1/0 Feed Pump 1 Start (PR1) / VFD Run I1/1...
Page 91 Chapter 5 — Input/Output Lists 5.2.2 - ADAC Two Tank OPTIONAL I/O Option 1: DA or Surge Level Switches Feed Pump 4 or Transfer Pump 3 Transfer Pump Flow/Pressure Switches DA Bypass Slot 5 - Digital Inputs - 24VDC 1769-IQ16 Address Name I5/0...
Page 92 Chapter 5 — Input/Output Lists Part No. 750-386...
Page 93: Chapter 6 - Parts
Chapter 6 Parts Parts List ................6-2 www.cleaverbrooks.com...
Page 94 Chapter 6 — Parts PLC Rack, Standard System Part Number Description Single Tank COMPACTLOGIX 750KB DI/O AI/O CONTROLLER 833-10039-000 required CONTROL,HMI,PANELVIEW PLUS 700, PVP7 833-11588-000 required PLC, TERMINATION CAP,RIGHT END COMPACTLOGIX 833-02838-000 required PLC, ANALOG OUTPUT MODULE COMPACTLOGIX, 4 CH 833-09946-000 optional MODULE,COMPACTLOGIX,W/16 24VDC INPUT...
Page 95 APPENDIX A - Variable Frequency Drive Parameters An asterisk * indicates the parameter needs to be changed from the factory default. A.1 - PF 70 PF70 Enhanced Control - ADAC 1000 Set parameter 196 to Advanced first. Par. No. Parameter Name...
Page 96 APPENDIX A - Variable Frequency Drive Parameters Autotune Calculate IR Voltage Drop Based on Drive Rating Flux Current Ref Based on Drive Rating Ixo Voltage Drop Read-Only Based on Drive Rating Autotune Torque Autotune Inertia Ready Start/Acc Boost Based on Drive Rating Run Boost Based on Drive Rating Break Voltage...
Page 97 APPENDIX A - Variable Frequency Drive Parameters PI Lower Limit -1000 -100.0% PI Upper Limit 1000 100.0% PI Preload 0.0 Hz PI Status Read-Only xxxx 0000 PI Ref Meter Read-Only PI Fdback Meter Read-Only PI Error Meter Read-Only PI Output Meter Read-Only PI BW Filter 0.0 Radians...
Page 98 APPENDIX A - Variable Frequency Drive Parameters Power Loss Mode Coast Power Loss Time 0.5 Secs Power Loss Level Read-Only Load Loss Level 2000 200.0% Load Loss Time 0 Secs Shear Pin Time 0 Secs Direction Mode Reverse Dis Reserved Read-Only AutoMan Cnfg XXXXXXXX XXXXXXX1...
Page 99 APPENDIX A - Variable Frequency Drive Parameters Testpoint 2 Sel Testpoint 2 Data Read-Only Fault Config 1 XXXXXXXX X1001X10 Reserved Read-Only Fault Clear Ready Fault Clear Mode Enabled Power Up Marker Read-Only Fault 1 Code Read-Only Fault 1 Time Read-Only Fault 2 Code Read-Only Fault 2 Time...
Page 100 APPENDIX A - Variable Frequency Drive Parameters Stop Owner Read-Only Start Owner Read-Only Jog Owner Read-Only Direction Owner Read-Only Reference Owner Read-Only Accel Owner Read-Only Decel Owner Read-Only Fault Clr Owner Read-Only MOP Owner Read-Only Local Owner Read-Only DPI Ref Select Max Freq Reserved Reserved...
Page 101 APPENDIX A - Variable Frequency Drive Parameters Anlg Out Config XXXXXXXX XXXXXXX0 Anlg Out Absolut XXXXXXXX XXXXXXX1 Analog Out1 Sel Output Freq Analog Out1 Hi Analog Out1 Lo Reserved Read-Only Reserved Read-Only Reserved Read-Only Reserved Read-Only Reserved Read-Only Reserved Read-Only Reserved Read-Only Reserved...
Page 102 APPENDIX A - Variable Frequency Drive Parameters Encoder Speed Read-Only Fdbk Filter Sel None Notch FilterFreq 0.0 Hz Notch Filter K 0.3 Hz Torque Ref A Sel Torque SetPt Torque Ref A Hi 1000 100.0% Torque Ref A Lo 0.0% Torque Setpoint1 0.00% Pos Torque Limit...
Page 103 APPENDIX A - Variable Frequency Drive Parameters A.2 - PF 400 Note: Set switches AO1 & AO2 to 20mA. Note: Set switches AI1 & AI2 to 20mA. Note: Set switch SNK/SRC to SRC. PowerFlex 400 - ADAC 1000 Par. No. Parameter Name Default Value Basic Display...
Page 104 APPENDIX A - Variable Frequency Drive Parameters Opto Out Logic Analog In 1 Sel 4-20 mA, 001 DIP Switch AI1 = 20MA Analog In 1 Lo 0.0% Analog In 1 Hi 100.0% Analog In 1 Loss Disabled Analog In 2 Sel 4-20 mA, 001 DIP Switch AI2 = 20MA Analog In 2 Lo...
Page 105 APPENDIX A - Variable Frequency Drive Parameters A163 Auto Restart Tries A164 Auto Restart Delay 1.0 Secs 5.0 (5 sec) A165 Start At Power Up Disabled Enabled, 001 A166 Reverse Disable Rev Disabled A167 Flying Start Enable Disabled A168 PWM Frequency 4.0 kHz A169 PWM Mode...
Page 106 APPENDIX A - Variable Frequency Drive Parameters d316 Elapsed Time-hr Read Only d317 Elapsed Time-min Read Only d318 Output Powr Fctr Read Only d319 Testpoint Data Read Only d320 Control SW Ver Read Only d321 Drive Type Read Only d322 Output Speed Read Only d323...
Page 107 APPENDIX A - Variable Frequency Drive Parameters A.3 - PF 700 PF700 - ADAC 1000 Note - Set parameter 196 to advanced first. Par. No. Parameter Name Raw Value Real Value Output Freq Read-Only Commanded Freq Read-Only Output Current Read-Only...
Page 108 APPENDIX A - Variable Frequency Drive Parameters Flux Current Ref Based on Drive Rating Ixo Voltage Drop Read-Only Based on Drive Rating Autotune Torque 50.0% Inertia Autotune Ready Start/Acc Boost Based on Drive Rating Run Boost Based on Drive Rating Break Voltage 1150 [Motor NP Volts] ×...
Page 109 APPENDIX A - Variable Frequency Drive Parameters PI Lower Limit -100 -100.0% PI Upper Limit 100.0% PI Preload 0.0 Hz PI Status Read-Only PI Ref Meter Read-Only PI Fdback Meter Read-Only PI Error Meter Read-Only PI Output Meter Read-Only PI BW Filter 0.0 Radians Accel Time 1 3.0 Secs...
Page 110 APPENDIX A - Variable Frequency Drive Parameters Load Loss Level 2000 200.0% Load Loss Time 0.0 Sec Shear Pin Time 0.0 Sec Direction Mode Reverse Dis Reserved Read-Only Save HIM Ref XXXXXXXX XXXXXXX1 Man Ref Preload Disabled Save MOP Ref XXXXXXXX XXXXXX00 MOP Rate 1.0 Hz/s...
Page 111 APPENDIX A - Variable Frequency Drive Parameters Reserved Read-Only Fault Clear Ready Fault Clear Mode Enabled Power Up Marker Read-Only Fault 1 Code Read-Only Fault 1 Time Read-Only Fault 2 Code Read-Only Fault 2 Time Read-Only Fault 3 Code Read-Only Fault 3 Time Read-Only Fault 4 Code...
Page 112 APPENDIX A - Variable Frequency Drive Parameters Direction Owner Read-Only Reference Owner Read-Only Accel Owner Read-Only Decel Owner Read-Only Fault Clr Owner Read-Only MOP Owner Read-Only Local Owner Read-Only DPI Ref Select Max Freq DPI Fdbk Select Speed Fdbk Data In A1 Data In A2 Data In B1 Data In B2...
Page 113 APPENDIX A - Variable Frequency Drive Parameters Anlg Out2 Scale Reserved Read-Only Reserved Read-Only Reserved Read-Only Reserved Read-Only Reserved Read-Only Digital In1 Sel Clear Faults Digital In2 Sel Digital In3 Sel Not Used Digital In4 Sel Speed Sel 1 Digital In5 Sel Speed Sel 2 Digital In6 Sel Speed Sel 3...
Page 114 APPENDIX A - Variable Frequency Drive Parameters Torque Ref A Hi 1000 100.0% Torque Ref A Lo 0.0% Torq Ref A Div Torque Ref B Sel Disabled Torque Ref B Hi 1000 100.0% Torque Ref B Lo 0.0% Torque Ref B Mult Torque Setpoint1 0.0% Pos Torque Limit...
Page 115 APPENDIX A - Variable Frequency Drive Parameters Write Mask Cfg Read-Only XXXXXXXX XX11111X Write Mask Act Read-Only Logic Mask Act Read-Only XXXXXXXX XX111111 PARAMETERS 600 and above NOT applicable Part No. 750-386 A-21...
Page 116 A.4 - PF 753 All IO wiring to module in Port 5 24V IO Module - 20-750-2262C-2R = Port 5 Set Input mode jmpers Ai0 & Ai1 to Current Mode (Port 5) PowerFlex 753 Drive - ADAC 1000 NOTES Par. No. Parameter Name...
Page 117 APPENDIX A - Variable Frequency Drive Parameters Stab Angle Gain 790.43 1648 IPM V FB HP Filt 15.0 1649 IPM SpdEst Filt 1000.0 R/S 1650 IPM SpdEst Kp 30.0 1651 IPM SpdEst Ki 2500.0 1652 IPM SpdEst KiAdj 75.0 1653 IPM Tran PWM 8.0 Hz 1654...
Page 118 APPENDIX A - Variable Frequency Drive Parameters DI Run Reverse 0.00 DI Jog 1 0.00 DI Jog 1 Forward 0.00 DI Jog 1 Reverse 0.00 DI Jog 2 0.00 DI Jog 2 Forward 0.00 DI Jog 2 Reverse 0.00 DI Manual Ctrl 0.00 DI Speed Sel 0 0.00...
Page 119 Max Fwd Speed 60.00 Hz 521-523 Parameters Not Modified Leave as Default Overspeed Limit 0.00 Hz 525-529 Parameters Not Modified Leave as Default Accel Time 1 3.00 Secs Parameters Not Modified Leave as Default J4 Jumper - Jumper Pins 1 and 2 (see illustration) Decel Time 1 3.00 Secs...
Page 120 A-26 Part No. 750-386...
Page 121 APPENDIX B - ADAC 1000 ProtoNode Tags APPENDIX B - ADAC 1000 ProtoNode Tags Tag list for use with the Cleaver-Brooks ProtoNode protocol translator. BACnet Modbus Address Description Origin Data Type Units Obj ID Data Type Address Alarms Deareator Status DAB1[0].0...
Page 122 APPENDIX B - ADAC 1000 ProtoNode Tags DAB1[2].10 Transfer Pump 2 VSD Bypass ADAC 1000 Boolean 10043 DAB1[2].11 Transfer Pump 3 VSD Bypass ADAC 1000 Boolean 10044 DAB1[2].12 Feed Pump Lead Lag Write Permissive ADAC 1000 Boolean 10045 DAB1[2].13 ADAC 1000...
Page 123 APPENDIX B - ADAC 1000 ProtoNode Tags DAB1[5].14 Spare47 ADAC 1000 Boolean 10095 DAB1[5].15 Reserved for CB - ADAC 1000 Dual ADAC 1000 Boolean 10096 DAB1[6].0 Surge Tank Level BAD QUALITY ADAC 1000 Boolean 10097 DAB1[6].1 Surge Tank Level HIGH...
Page 124 APPENDIX B - ADAC 1000 ProtoNode Tags DAB1[9].1 Spare72 ADAC 1000 Boolean 10146 DAB1[9].2 Spare73 ADAC 1000 Boolean 10147 DAB1[9].3 Spare74 ADAC 1000 Boolean 10148 DAB1[9].4 Spare75 ADAC 1000 Boolean 10149 DAB1[9].5 Spare76 ADAC 1000 Boolean 10150 DAB1[9].6 Spare77 ADAC 1000...
Page 125 APPENDIX B - ADAC 1000 ProtoNode Tags DAR1[39] Surge Header Pressure ADAC 1000 Real 30077 DAR1[40] Surge Tank Temperature ADAC 1000 Real Degrees F 30079 DAR1[41] Surge Tank Water Level ADAC 1000 Real Inches 30081 DAR1[42] Surge Tank Feed Water (MUV) Signal...
Page 126 APPENDIX B - ADAC 1000 ProtoNode Tags DAI1[27] Spare142 ADAC 1000 Integer 30158 DAI1[28] Spare143 ADAC 1000 Integer 30159 DAI1[29] Spare144 ADAC 1000 Integer 30160 DAI1[30] Spare145 ADAC 1000 Integer 30161 DAI1[31] Spare146 ADAC 1000 Integer 30162 DAI1[32] Spare147 ADAC 1000...
Page 127 APPENDIX B - ADAC 1000 ProtoNode Tags DAWI[7] TP 2 LEAD/LAG Order Integer 40008 DAWI[8] TP 2 LEAD/LAG Order Integer 40009 DAWI[9] Integer 40010 DAWI[10] Integer 40011 DAWI[11] Integer 40012 DAWI[12] Integer 40013 DAWI[13] Integer 40014 DAWI[14] Integer 40015 DAWI[15]...
Page 128 APPENDIX B - ADAC 1000 ProtoNode Tags Part No. 750-386...
Page 129 APPENDIX C - Loading a PLC Program APPENDIX C - Loading a PLC Program Loading a PLC program from an SD card to an L33ER or L24ER processor. Required Hardware: • SD card: Every PLC processor should come with an SD card from Rockwell Automation.
Page 130 APPENDIX C - Loading a PLC Program 7.Close the WinZip program. 8.The Logix folder should now be extracted to the SD card. The logix folder must be at the root directory of the SD card. No other files should be present on the SD card. Use Windows Explorer to verify the Logix folder on the SD card.
Page 131 APPENDIX C - Loading a PLC Program 10. Install the SD card into the PLC SD card slot. The PLC switch should be in REM. 11.Cycle power to the PLC. 12.The transfer from the SD card to the PLC processor will begin. Please be patient while the installation is in progress, the whole process from power up to completion may take up to 3 Minutes.
Page 132 APPENDIX C - Loading a PLC Program Part No. 750-386...
Page 133 APPENDIX D - Deaerator Reference Drawings APPENDIX D - Deaerator Reference Drawings Water Levels Part No. 750-386...
Page 134 APPENDIX D - Deaerator Reference Drawings Differential Pressure Level Control Differential Pressure Level Control and DA Tank Pressure Control (1 of 2) Part No. 750-386...
Page 135 APPENDIX D - Deaerator Reference Drawings Differential Pressure Level Control and DA Tank Pressure Control (2 of 2) Part No. 750-386...
Page 136 APPENDIX D - Deaerator Reference Drawings Major Components, DA with ADAC [typical] Part No. 750-386...
Page 137 APPENDIX D - Deaerator Reference Drawings Major Components, Surge Tank with ADAC [typical] Part No. 750-386...
Page 138 APPENDIX D - Deaerator Reference Drawings Duo Tank Components [typical] Part No. 750-386...
Page 140 Web Address: http://www.cleaverbrooks.com...

CleaverBrooks ADAC 1000 Operation Manual

Chapter 1 - General

Chapter 2 - System Components

Chapter 3 - Commissioning

Chapter 4 - Operation

Chapter 5 - Input/Output Lists

Chapter 6 - Parts

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