Instructions 24H372 ACS Module 3A0006D EN Advanced Motor Control System for Graco E-Flo® Electric Circulation Pumps. See page 4 for Required System Components. For professional use only. Not approved for use in explosive atmospheres or hazardous locations. Important Safety Instructions Read all warnings and instructions in this manual and in your E-Flo pump manuals. Save these instructions.
Related Manuals Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Required System Components . . . . . . . . . . . . . . 4 Optional Components . . . . . . . . . . . . . . . . . . . . . 4 E-Flo Pump Operational Overview . . . . . . . . . . .
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Overview Overview Required System Components Optional Components NOTE: The following components must be installed in every ACS system. Optional ACS components can be ordered through your Graco Distributor. 24J305 Sensor Circuit Kit for E-Flo Pump (Series D and later) 15V342 Ethernet Switch Verify that the 24J305 Sensor Circuit Kit is installed on your E-Flo Pump. If the pump does not have the sensor circuit, order Part No. 24J305.
Overview E-Flo Pump Operational Overview An electric motor (B) provides input to a 75:1 gear reducer (GR), which drives two fluid pumps (FP). See FIG. 1. The stroke positions of the two pumps are offset to achieve consistent flow from the pump assembly. See FIG. 2. The optional sensor circuit includes a top dead center (TDC) sensor to measure motor speed, a position sensor (PS) to measure motor position, and a pressure transducer (PT) to measure fluid pressure at the pump outlet.
Installation Installation Indicators and Pushbutton All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations. FIG. 3 shows the ACS Module indicators and POWER INTERRUPT pushbutton. See also FIG. 4 and FIG. 5. FIG. 3 shows the ACS panel. See FIG. 4, and FIG. 5 for schematic diagrams showing wiring connection points of all required and optional system components. See FIG. 6 for a detailed schematic of VFD, Barrier, and Start/Stop connections.
Installation Critical Item Checklist ❑ Wire according to FIG. 4 on page 8 and FIG. 5 on page 9. ❑ Use Belden 8777 cable or equivalent. It is important to use multiconductor cable with 3 individually shielded pairs. ❑ Ferrite (15D906) must be installed on pressure transducer wires. ❑ Do not place signal wires in the same conduit as AC Power wires. For example, the TDC/Position sensor wires should not share a conduit with the VFD wires.
FROM 16A630 9 8 8 7 FROM VFD FROM 16A633 14 7 15 8 CONNECTION DETAILS (22A-D8P7N104) ALLEN BRADLEY VFD EXAMPLE: 3 PHASE AC IN ACS MODULE LINE LOAD R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 ANALOG DRIVE SIGNAL RS485 COMS / 24VDC POWER 15 6 5 4 3 2 11 02 12 03 11 +24VDC 06 DIGITAL IN 2 05 DIGITAL IN 1 04 COM 03 RUN/REV 15 4-20ma IN 16 RS485 SHLD OUTPUT T1/T2 OR T2/T3 OR T3/T1. ACS ANALOG VFD + AT FAN.
3A0006D PROOF CONDUIT EXPLOSION WIRING DETAIL DISABLE SECURE RESET START/STOP OPERATION STATION EXPLOSION PROOF CONDUIT RESET START / STOP SECURE / DISABLE OPERATOR STATION 3 PAIRS INDIVIDUALLY SHIELDED CABLE BELDEN 8777 OR EQUIV WITH FERRITE (123375) (SEE MANUAL FOR DETAILS) WIRING DETAIL E-FLO PUMP JUNCTION BOX HAZARDOUS RED GRN WHT BLK +BRN -BLU E-FLO FERRITE (16G496) 1 2 J1 3 4 5 1 2 +BRN -BLU PRESSURE TRANSDUCER TDC SENSOR POSITION SENSOR IS CIRCUIT E-FLO JUNCTION BOX PRESS
3A0006D FIG.
Installation Location This equipment is not for use in explosive atmospheres. Do not install equipment approved only for non-hazardous location in a hazardous area. Install the ACS Module and components in a non-hazardous area. Mounting See Dimensions, page 43. The ACS Module and associated components are designed to be mounted on a DIN rail inside of the motor control enclosure. The ACS Module DIN rail bracket may be reversed if desired, to accommodate installation requirements.
Installation ACS Modbus Registers Modbus Registers 401800 to 401828 are used for ACS system control and setup. See Table 2. Table 2: ACS Modbus Registers 401800 to 401828 Register No. Register Name Description 401800 None Not used. 401801 Model Sets the pump model. Range of 1-4: 0 = Not used 1 = E-Flo 1500 2 = E-Flo 2000 3 = E-Flo 3000 4 = E-Flo 4000 401802 Units 0 = US GPM/PSI; 1 = Metric LPM/BAR 401803 ClrCtrFlg Clear the Cycle Counters: 1 = Clear Batch Total. 2 = Clear Grand Total.
Installation Table 2: ACS Modbus Registers 401800 to 401828 Register No. 401812 Register Name PressAlrmEnable Description 0 = No alarms. 1 = High Pressure only. 2 = Low Pressure only. 3 = High and Low Pressure. 401813 Press_Mon Indicates to the system that a transducer is present to read. 1 = Enable pressure transducer reads. 0 = Disable pressure transducer reads.
Installation Modbus Registers 401900 to 401950 provide ACS operation status information and are Read only. They must never be written to. See Table 3. Table 3: ACS Modbus Registers 401900 to 401950 Register No. Register Name Description 401900 None Not used. 401901 CalcCPM Pump cycles per minute x 100. 401902 GT_CyclesL Grand Total cycles low word. 401903 GT_CyclesH Grand Total cycles high word.
Installation Table 3: ACS Modbus Registers 401900 to 401950 Register No. Register Name Description 401924 HeartBeat Alternately set to 1 and 0 every second. This indicates that the ACS program is operating. 401925 DriveCmdHz Current drive speed command x 10; ie, 0 to 800 = 0 to 80 Hz. 401926 Current_Alarm Represent the current alarm code. Alarm Code No.
ACS Control Mode ACS Control Mode The ACS module provides an analog drive signal to the VFD. 120373 UL/CSA Control Box • Run command refers to an input command to the VFD, requesting the motor to run in designated direction. • Stop command refers to an input command removed, requesting the motor to stop running.
Operation Operation Set up a Static IP Address for the Computer NOTE: Screen views in this manual are shown using Microsoft Windows XP. NOTE: To run the program, Java Version 6 Update 10+ (Version 7 not compatible) must be loaded on your computer. This is a free download. 1. Before connecting your computer to the ACS, verify that Java Version 6 Update 10+ (Version 7 not compatible) is loaded on your computer. To verify, go to Java.
Operation 3. Before running the software you must manually assign an IP address to your computer: a. On your computer, click on the Start button to open the menu, then click on Control Panel b. See FIG. 9. Double click on Network Connections. Double click on Local Area Connection to open the Local Area Connection Status window. Click on Properties to open the Local Area Connection Properties window. See FIG. 10. . FIG. 9.
Operation c. In the Local Area Connection Properties window (FIG. 10), scroll to Internet Protocol (TCP/IP) and double click, to open the Internet Protocol (TCP/IP) Properties window (FIG. 11). f. Type in the following Subnet mask: 255.255.255.0 NOTE: To reconnect to the user network, change the setting back to “Obtain an IP Address Automatically.” g. Click on OK to accept the changes and close the Internet Protocol (TCP/IP) Properties window. h.
Operation NOTE: Verify that the wireless connection is turned off (disabled) before performing step 4. able field, then click to enter. 4. In a web browser, enter: http://192.168.1.5:9080 5. Press Enter. The ACS Module Setup Screen appears. See FIG. 12. 6. Each ACS module is provided with a default IP address (192.168.1.5). The assigned ACS IP address must be different from any other IP address in the network. Only the last digit of the address is editable. Type a new number in the edit- 7.
Operation ACS System Status Screen See FIG. 13. The System Status screen appears when the ACS Module is powered up. The screen displays the current conditions and status of up to 50 pumps (numbered 0-49) in the system. NOTE: The Visual Basic software program for the ACS Module is available as a free download from www.graco.com/Finishing. Navigate to the E-Flo Pump product page for the download link. Click on a Pump Name key to open the Run screen for that pump. FIG. 14 shows the Run screen.
Operation Run Screen See FIG. 14. Use the Run screen to start or stop the pump, reset faults, access the Configuration or Alarm screen, view setpoints, and monitor the pump’s operation by viewing performance data. Pressure Setpoint The Run screen displayed depends on which pump was selected on the ACS System Status Screen, page 21. Each Run screen applies only to the selected pump.
Operation Config Button Alarms Button Click on the Config key to open the Configuration screen. See page 24. Click on the Alarms key to open the Alarms screen. See page 31. Pump Name, ACS IP Address, Date, and Time Pump Performance Data Pump Setpoints Run Key Motor Status Display Fault Display Reset Fault Key Stop Key Click to open Configuration screen (page 24). Click to open Alarm screen (page 31). FIG. 14.
Operation Configuration Screen See FIG. 15. Use this screen to set the configuration for each pump. Transducer Calibration (see page 28) System Diagnostics (see page 30) Pump Parameters (see page 25) System Features (see page 27) Run and Sleep Setpoints (see page 27) Reset Totals (see page 29) Alarm Settings (see page 29) Set the Clock (see page 28) Software Levels (see page 30) FIG. 15.
Operation Set Pump Parameters Measurement Units Click on the button to view the drop-down menu. Select the desired units of measure: • • US Units (gpm and psi) Metric Units (lpm and bar) NOTE: Changing the measurement units will stop the pump. FIG. 16. Pump Setup Fields Select Pump Model Click on the button to view the drop-down menu. Select the pump being controlled and monitored by the ACS module. See FIG. 17. The selection activates a flow rate setpoint range, based on the size of the pump selected.
Operation Select Control Mode Select Language Click on the button to view the drop-down menu. Select the desired control mode: Click on the button to view the drop-down menu. Select the desired language: • • • • • • • • • • • • • Flow (The pump will run at a constant flow rate) Pressure (This selection turns on Cam Mode and Pressure Transducer Enable, see page 27. The pump will make two revolutions before entering pressure control mode.The pump will vary speed/flow to maintain a constant pressure.
Operation Select System Features Run and Sleep Setpoints See FIG. 21. Check the Sleep Enable box to turn on the Sleep mode. Sleep mode will remain on until it is turned off. Auto Decrement Auto Decrement helps extend pump life by operating the pump at the lowest speed necessary to maintain the selected pressure range. Auto Decrement is operable in pressure mode only.
Operation Calibrate the Transducer Set the Clock NOTE: Only a 4-20 mA output transducer can be used with the ACS. On the Configuration screen, click on NOTE: Calibration values for a Graco transducer are listed on the label attached to the pump gearbox circuit board cover. See FIG. 23. For a non-Graco transducer, refer to the manufacturer’s label or data sheet. (see FIG. 25).
Operation Reset Totals Alarm Enable The screen displays the batch total and grand total cycles for each ACS module. There are two alarm pressure fields: Maximum Pressure and Minimum Pressure. Check the boxes to enable the • alarms. Click on the buttons to raise or lower the pressure setpoints, as desired. These values are expressed in psi or bar. To reset the batch total, click on . FIG. 28. Alarm Settings Click to reset batch total FIG. 26.
Operation System Diagnostic Indicators See FIG. 29. The diagnostic indicators light under certain conditions, as detailed in the following paragraphs. Motor Running Light is on steady when the motor is running. ACS Heartbeat Light blinks when power is supplied to the ACS. Maximum Flow Warning Lights if the maximum flow setpoint exceeds the pump’s capability. Transducer Lights if the system detects a pressure transducer is present. ACS ID# Automatic input (Modbus node number). Not editable.
Operation Alarms Screen See FIG. 30. The Alarms screen logs the date, time, and description of each alarm. See page 41 for descriptions and explanations of each alarm/warning. Click to refresh the screen. FIG. 30.
ACS Software Update ACS Software Update This process is required to load files to the Graco ACS module for an upgrade of the ACS application software. The process allows update of application software through the Ethernet port. It is critical that the directions be followed in the correct order and with detail. Required data and equipment: • The Graco Firmware file will be loaded through the web browser. It will be 16J859G.CO5 (or a file of this format with a xxx.CO5 extension of a later version).
ACS Software Update 3. When the Digital Signature Verification window appears, click Run. Be sure that the “Always trust content from this publisher” box is not selected. See FIG. 32. Click Run Do Not Select FIG. 32.
ACS Software Update 4. Open Mozilla Firefox web browser. In the address bar enter: http://192.168.1.5:9080. See FIG. 33. Enter http://192.168.1.5:9080 Use this page for configuring the ACS module after the latest firmware upgrade to 1.02. FIG. 33. Standard ACS Module Setup Page 5. Click the button first. See FIG. 34. DO THIS FIRST FIG. 34.
ACS Software Update 6. Click the button, then the button. The Get Device ID and Get Device IP values must be populated on the page before installing the new ACS software. See FIG. 35. GET DEVICE ID and GET DEVICE IP values must be populated on the page before installing the new ACS software. FIG. 35.
ACS Software Update 7. Click the button and navigate to the 16J859G.C05 (or later revision) file. Click the button when the file link is loaded. See FIG. 36. Click Browse and navigate to the 16J859G.C05 (or later revision) file. Click Program ACS when the file link is loaded. FIG. 36.
ACS Software Update 8. After performing steps 6 and 7, the screen will show window pop ups while the software is downloading to the ACS module. See FIG. 37. If necessary, move the window to view the line numbers incrementing. Line numbers will increment to 2200+ when the download is complete. FIG. 37.
ACS Software Update 9. Click OK when the download is complete. The popup window will clear automatically. See FIG. 37. Click OK when download is complete. Window will clear automatically. FIG. 38. Click OK When Download is Complete NOTE: A new feature allows for setting of the default IP Address of “192.168.1.5” if you cannot remember the previous configured IP. To reset to the default IP Address: 38 • Power OFF the ACS Module. • Activate the RESET INPUT (or short to ground/common) and HOLD.
ACS System Setup Checklist ACS System Setup Checklist 1. Pressure Sensor Calibration NOTE: Only a 4-20 mA output pressure transducer can be used with the ACS. NOTE: Calibration values for a Graco transducer are listed on the label attached to the pump gearbox circuit board cover. See FIG. 23, page 28. For a non-Graco transducer, refer to the manufacturer’s label or data sheet. NOTICE Pressure sensor calibration information must be entered into the ACS control module.
ACS Features ACS Features Drive Active (System ON) Output The output can be mapped to most of the parameters. The most common is Drive Enable. This relay output will be closed when ACS module is running. It is used as the Start or Run input to the VFD. It is not the Secure Disable input. See FIG. 4-FIG. 6 on pages 8-10 for further information. Operational Envelope Limit Explosion-proof electric motors have constant torque and variable torque limits.
Diagnostic Procedures Diagnostic Procedures The ACS module contains two diagnostic LEDs: • POWER ON: Solid green when the ACS is powered and the pump is running. • DRIVE ENABLED: ON (solid red) if the pump is stopped and the drive enabled relay is open. OFF if the pump is running and the drive enabled relay is closed. Table 7: Faults and Diagnostic Procedures Fault Description Diagnostic High Pressure (System pressure is higher than the entered high pressure trip point.) 1.
Diagnostic Procedures Table 7: Faults and Diagnostic Procedures Fault Description Diagnostic No TDC Signal (Top Dead Center Sensor is not detected, or motor is not able to develop torque, and therefore cannot put the pump into motion) No TDC Signal: 1. Verify that output shaft is turning. 2. Check all of the wiring. 3. Verify that sensor is operational. Remove PCB cover and monitor LED light on the top of the sensor.
Technical Data Technical Data Inputs Power: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog inputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital inputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outputs 4-20 mA loop:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital outputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
