Graco 3A0006EN-D User's Manual
Contents
1. Dere KB ID 6 Dewite IP 192 168 1 5 GET DEVICE ID GET DEVICE IP NODE ID SETUP Enter New ID Click Browse and navigate to the D ruwa UBED by watar E Modder 16J859G C05 or later revision file IP ADDRESS SETUP Sat P Address Barlow Note This version allows changes to the 4th address e 192 168 1 5 SET IP ADDRESS The IP shown above is the default after Page R The ACTUAL IP address is in the Address Bar wis pagel Click Program ACS when ACS SOFTWARE INSTALLER the file link is loaded F Adobe Acro Graco wL H 7 FiG 36 Browse Button and Program ACS Button 36 3A0006D 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 ACS D Assignment Marilla T inet CS ID ama gt 192 168 1 5 3050 E4 sj Most dated Getting Started JA Latest Hinadiees 5 Best d the Web hrel guie teret Shert Microsoft Makita arte et Wish Sice Galery te If necessary move the window to kasu view the line numbers incrementing kazilla Firefox TAE 68 1 i ACS Server Remont OR 1 Sendag fret GBU 1230 GEU 1 CZ p bemi Sending il C ZO02 A ZE 5 0 1 C92. U U U U U U FiG 13 ACS System Status Screen 3A0006D GC lG lG lG lG lG lG lG lG lG lG lG lG lG lG lG lG lG l C page 20 E x IP Address Z 132 1B8 1 132 1B58 1 192 1B8 1 192 1B8 1 192 168 1 192 168 1 192 1B8 1 192 168 1 192 168 1 192 168 1 492 168 1 492 168 1 192 168 1 192 168 1 192 1B8 1 192 1B8 1 132 1B58 1 192 168 1 192 1B8 1 192 1B8 1 132 1B58 1 Pressure Status Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Offline Refresh IP s Configuration E Flo 4000 O G 21 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 opera tion by viewing performance data 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 Information Bar The Run screen information bar displays the unique pump name the ACS IP address the date and the time The Pump Name is not editable on the Run screen but may be input on the Configuration screen See page 24 Pump Performance Data Pump Speed The pump speed is displayed in cycles per minute CPM Flow The flow is expressed in g
3. 314011 Reset Batch Alarm Enable BA Max Pressure C Min Pressure Transducer Calibration see page 28 System Diagnostics see page 30 BER Cal High FSI Cal Low PSI Cal High mA Cal Low mA Running Cycles Batch Total Grand Th esr N ACS IDF ACS Software Rew NPC Software Rev i H 17 2 9 48 Software Alarm Settings Set the Clock Levels see see page 29 see page 28 page 30 3A0006D Set Pump Parameters Kiodel E Flo 4000 Units English Control Made Flow Pressure Setpoint 180 Pump Mame Pump Language English 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 NOTE Changing the pump model will stop the pump JE Flo anon E Flo 1500 Units E Flo 2000 E Flo 3000 E Flo 4000 Model Control hiode Pressure Setpoint 180 Pump Mame Pumpi Language English FiG 17 Pump Model Drop down Menu 3A0006D Operation Measurement Units Click on the button to view the drop down menu Select the desired units of measure e US Units gpm and psi e Metric Units lpm and bar NOTE Changing the measurement units will stop the pump Mannie E Flo 4000 Units n h Control Mode ee Setpoint Pump Name Pu
4. ETHERNET COMS MONITOR PLC CONTROL OPTIONAL ETHERNET ROUTER SWITCH 3A0006D 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 haz ardous 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 Remove the screws turn the bracket 180 and reat tach DIN rail bracket may be reversed if desired ti17553a Ground the ACS Control Module The equipment must be grounded Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit Ground the ACS Module through a proper connection to a power source 3A0006D 11 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 401801 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 CirCtrFlg Clear the Cycle Counters 1 Clear Batch Tot
5. See FIG 21 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 It reduces the flow rate incremen tally by 1 Hz every 1 second until the Run Flow Setpoint is reached while still maintaining target pressure Auxiliary Relay On Enables peripherals such as a back pressure regulator Cam Mode Enables the Cam profile If turned off pressure mode is disabled Sensor Fault Override Check this box to allow the pump to continue to run if the TDC or Position sensors fail The pump will run in flow mode Transducer Fault Override Under normal operation the ACS will shut down the pump if the transducer fails Selecting Transducer Fault Override bypasses that safeguard and allows the pump to continue to run This selection cannot be made on this screen it can only be selected through Modbus Pressure Transducer Enable Check this box if a pressure transducer is monitoring the pressure This is automatically enabled if Pressure is selected as the Control Mode see page 26 Auto Decrement Aux Relay On CAM Mode Sensor Fault Override Transducer Fault Override Pressure Transducer Enable FIG 21 System Features Menu 3A0006D Operation Run and Sleep Setpoints Check the Sleep Enable box to turn on the Sleep mode Sleep mode will remain on until it is tu
6. 1 5 DAR Set Clock Hour Minute Second Year Month Fic 25 Set the Clock O 3A0006D Reset Totals The screen displays the batch total and grand total cycles for each ACS module e To reset the batch total click on Reset Batch Running Gycles Batch Total rand Total 15751 112212 Reset GT Reset Batch Click to reset batch total FiG 26 Reset Batch Total Toresetthe grand total click on ResetoT You will be prompted to confirm the selection Warning ing Cycles T Grand Total Are You Surer g 112212 Yes Reset GT 1 Click to reset grand total 2 Click to confirm FiG 27 Reset Grand Total GT 3A0006D Operation Alarm Enable There are two alarm pressure fields Maximum Pressure and Minimum Pressure Check the boxes to enable the ae alarms Click on the gt buttons to raise or lower the pressure setpoints as desired These values are expressed in psi or bar Alarm Enable Pal Max Pressure 250 Min Pressure E FiG 28 Alarm Settings 29 Operation System Diagnostic Indicators See FIG 29 The diagnostic indicators light under cer tain 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 i
7. 10 Local Area Connection Properties Window d See FIG 11 Set to Use the following IP address NOTE The IP address being created in step e must be different from any other IP address used in the network e Type in the following 10 characters including the dots 192 168 1 then type additional numbers for example 201 to create a unique IP address for the computer 3A0006D Operation 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 win dow h Click on OK to close the Local Area Connection Properties window i Close the Local Area Connection Status win dow and Network Connections window Internet Protocol TCP IP Properties xl General this capabiliif Othenwise you need to ask your network administrator for the approggate IP settings tain an IF address automatically te Use the following IP address IP address 192 168 1 201 Subnet mask 255 255 255 Default gateway a Obtain DHS server address automatically te Use the following ONS server addresses Preferred ONS server Alternate ONS server I Advanced Fic 11 Internet Protocol TCP IP Window 19 Operation NOTE Verify that the wireless connecti
8. ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Glossary of Terms Term Description ACS Advanced Control System VFD Variable Frequency Drive TDC Top Dead Center measures position of pump drive I O Input output PCB Printed Circuit Board Run Set of commands enabling motor to run in designated direction Stop Set of commands authorizing motor to stop running 3A0006D 3 Overview Overview Required System Components NOTE The following components must be installed in every ACS system 24J305 Sensor Circuit Kit for E Flo Pump Series D and later 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 The kit contains the cir cuit board and TDC position and pressure sensors necessary to utilize the Graco ACS module taking advantage of flow control and pressure control mode delivered by Graco ACS software See manual 311603 For E Flo Pumps Series C and earlier check with your local Graco Distributor for compatibility 16D612 Power Module Assembly Transforms AC power to a 24 Vdc power s
9. Repair Parts Manual 311603 24J305 Sensor Circuit Option 311690 4 Ball Lowers with open wet cup 3A0539 4 Ball Lowers with enclosed wet cup Set up a Static IP Address for the Computer 17 ACS System Status Screen 21 RUA SCEN 4c aka oad eee wee EAR ee 22 Configuration Screen 24 Alarms Screen 31 ACS Software Update 32 ACS System Setup Checklist 39 ACS Features ak uruya Bae Sok Sol hh ea aes 40 Drive Active System ON Output 40 Back Pressure Regulator BPR Production Sleep MOES LL ym ae a ee baited oa eee ete eek 40 Flow Rate Monitoring aaa aaa aana 40 Operational Envelope Limit 40 Pressure Limits 40 Diagnostic Procedures 41 Technical Data fais soto ee LE S 43 DIMENSIONS correa raaa r rr week 43 Graco Standard Warranty 44 Graco Information 44 3A0006D Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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
10. enum 2 Smig 001CF00060001C171ESA2025004 m01CF3345 inenen 3 Sending 01 CF0844770000038F4ERS4FF Cl GOLCH kenam Seming G01 CE L 0DB 2 1000000000000 184 GEU 1 CTE S binene Sein DU 1 CF LBO0O0000000000000051 SI 01 CE3 5 inna 1 Send G001CF2053445451000009000000 C 771 OCR 8 tree w ERER wa Lre Meri Hpi re Line numbers will increment to 2200 iia ies when the download is complete Fic 37 Window Popup During Software Download 3A0006D 37 ACS Software Update 9 Click OK when the download is complete The popup window will clear automatically See FIG 37 Ble Edt Wee Hetoy cimos poh Heb E ACS ID Assignenere Ey C ias By Most veted Getting Started B Latest Headines sa Best of the Web Channel Guide _ Internet Start C Merosot Miresoft Suggested Stes Web Skee Gallery sa Stari ACS Server ResponseOR 1 Sending first 06C237 GO6CI37 knenum 1 Sending IU ZDA ZA ZC UL ZE LInenurn 2 Sending 006CF0000001C171E5A 202800 06CF43 knenum 3 sending m06CF08344770000038F4FB393FF 06CF43 knenun4 I Sending 06CF 100B2 1 000000000000123 06CF43 Enenum 5 Sending m06CF1800000000000000005151 06CF43 inenum 6 Sending 06CF 205344545 1000000000000 LS 25 Enem 7 R 2 BCB wi a Ace 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 pr
11. not share a conduit with the VED wires L Use the following VFD configuration settings analog input scaling 4 mA 0 zero Hz 20mA 80 Hz Acceleration rate 1 0 second for full range 0 80 Hz e Deceleration rate 0 5 second for full range 80 Hz 3A0006D 7 Installation qTHS S8rSt 9 L GSA SO TVNV SOV ATavsid AYNOAS LNdNI dOLS 10 NI BWOZ r SL TET G4A 9OTVNV SOV NI OGAOL O 1 OGAOL ZL OdAre LL HOLOW WOuS Z NI IWLIDIC 90 GS LOANNOO L NI TV LI IG SO uv S3aHIAA WOO pO HOLSIWHAHL A3Y NNY 0 3HnSN3 GM4 NNUY ZO YOLOW O143 HOLIMS SOV OL FINGOW SOV JIVL3G SNIHI A OL13S34Y GSA A31qdyvt8 N3TIV JIdNYXI a 18gvsiqd 209nO2S 1 dNI dOLS LYVLS 40 LdNYALNI NYV TY NJJH9S H NOL SNOILYOINAWNOO INOtid HO 1d WOtid LNdNI SGOW dass 8 339930 Yad a33ds qauinoOatu OL SAILV TAY LNO SOTVNV FANYA 930 NOILISOd SALVINOWOD ISd 00S 0 wOVEdsass JHNSSIJHd LWOZ OL Y LNdNI OGL SJ1ANYH IOHLNOO SOV oded tidlHtiVg HOSN3S tH3allHtHHV8 ewoz y NOILISOd GNV OGL YAONGSNVYL AHNSSAYd OOO 000 000 000 poopoo v S San NOWWOO OA pZ ce9v9 U p _ Q ieee Haig ewoz y u ma YAONGSNVHYL 3unssatid mi O qatu I r NOWWOO O R O 9V9l SONT I NOILISOd NOILISOd us LHM SOd uNOu SAHOLIMS TIY os ya v er 9al tigdltttivg HOSN3S SOd NOILISOd GNV OGL SOd 0AL NH9 ef 9G1 OqQ1L 03 TIVLAC ONIYIM S C dalduv
12. ss 59 a R A 06 99 10 90 relative humidity non condensing Dimensions ACS Module NOTE Designed for DIN rail mounting ti17553a 3A0006D 43 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 This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment
13. BPR Production Sleep Modes NOTE See FIG 4 FiG 6 on pages 8 10 and manual 311606 for wiring and installation details Flow Rate Monitoring Table 5 E Flo Pump Displacement Volumes Volume per Volume per Cycle cc Cycle Gal 4278 1 13 Lower Size 2000cc 1000cc 1537 0 41 1500cc 3070 0 81 750 cc 40 Operational Envelope Limit Explosion proof electric motors have constant torque and variable torque limits E Flo system is a constant torque application and therefore the motor s constant torque limits must not be violated The system is avail able from Graco with two motors the UL CSA explo sion proof motor and the ATEX explosion proof motor Pressure Limits If a pressure transducer is present set the maximum pressure limits as shown in TABLE 6 See Alarm Enable page 29 Table 6 System Pressure Limits E Flo a ee psi se E Flo 4000 2000 E Flo 3000 1500 33 23 Non Graco Motor bar 3A0006D Diagnostic Procedures Diagnostic Procedures The ACS module contains two diagnostic LEDs e POWER ON Solid green when the ACS is powered and the pump is running e 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 Fault Description High Pressure System pressure is higher than the entered high pressure trip point Low Pressure System pressure is lower
14. E This warning only occurs in pressure mode Cam mode is not functional due to loss of TDC or position sensor signal required for CAM operation Verify wiring is shielded and installed correctly See Schematic Diagrams page 8 Start Event ACS has received a start command Stop Event ACS has received a stop command 3A0006D 41 Diagnostic Procedures Fault Description 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 Position Sensor Sig nal Position Sensor is not detected or motor is not able to develop torque and therefore cannot put the pump into motion 42 Table 7 Faults and Diagnostic Procedures No TDC Signal Verify that output shaft is turning Check all of the wiring Verify that sensor is operational Remove PCB cover and monitor LED light on the top of the sensor The light should be normally on and it should be off for only short period of time when top dead center is reached Stall 1 Relieve system pressure 2 Check lowers slider cylinders and output shaft with connecting rods for visible damage If no damage is visible check for excessive heat which is a sign of fric tion Check the system control circuit wiring Check that the motor is turning If not check motor wiring Disconnect lowers and try running just the motor and gearbox No Position Sensor Signal 1 Verify that outp
15. Instructions gt g GRACO 24H372 ACS Module kisuta 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 Read all warnings and instructions in this manual and in your E Flo pump manuals Save these instructions ee Important Safety Instructions ti17553a L PROVEN QUALITY LEADING TECHNOLOGY Related Manuals Contents Related Manuals 2 WAar i gS soo eee en be eae ean kl ea asuaka 3 Glossary of Terms 3 OVEFVIEW u LS N N cca re at eee eet eee 4 Required System Components 4 Optional Components nananana 4 E Flo Pump Operational Overview 5 Installation 6 Inputs and Outputs 6 Indicators and Pushbutton 6 Critical Item Checklist n n anaana aaan 7 Schematic Diagrams 8 LOCAUOM sigs thes eee BER e ek eRe 11 NIG es eo mney eee na tnt aot ht Bian Rh te de Z 11 Ground the ACS Control Module 11 ACS Modbus Registers 12 ACS Control Mode 16 Op raU m ce yu K NR cit pale aut upataqa ea eters 17 Related Manuals Manual Description 311592 E Flo Installation Manual 311593 E Flo Operation Manual 311594 E Flo
16. LS YOLVYsdO STIVLAG 4O04 IWNANVW 349 TIVLAG SNIHIAA XOd NOILONNP dNNd 074 3 SNOCYVZVH w gt O UU GC O N N N Les z UU le l UU m FiG 5 System Schematic Diagram Hazardous Area 3A0006D Installation aunssatud K E EJE EE S BBB SIS SOd OGL NZ SYHSIYYVE E FLO N SOd O01 3HNSSAYd ANALOG DRIVE SIGNAL d1Evsid AYNOAS OPERATOR STATION YAMOd ASVHd E FLO 3 SOd OGL e SualHuvg SOd O01 3HNSSAYd ANALOG DRIVE SIGNAL 3 18vSIq 13d3S3qd dOLS LYVLS AYNOAS OPERATOR STATION YAMOd ASVHd BRRR SEL sisisi 8 SOd OdGL o SYFIYYVE N E x O LU SOd OUL AHNSSAYd ANALOG DRIVE SIGNAL 318vsiq TaSau dOLS 7LYVLs sundas OPERATOR STATION YAMOd ASVHd E FLO 1 BERR E alsi s SOd O0L L Sdalduvgd SOd O01 3HNSSAYd ANALOG DRIVE SIGNAL d1gEvsid AYNOAS 1 25209 dOLS LYVLS OPERATOR STATION YAMOd ASVHd NON HAZARDOUS HAZARDOUS Fic 6 Detailed Schematic Connections to VFD 10 N JINGOW SOV C ooooo c FINGOW SOV C ooooo L JINGOW SOV C 00000 OOOOO O OD O OOOD O O OD O O OD O GENERIC GENERIC VFD 3 GENERIC VFD 2 GENERIC VFD 1 VFD N JHdNSSJHd E l I JINGOW SOV 7 sunssaud Z e j3unssau Z w 24 VDC
17. ODULE SETUP ACS Software Version 1 02 GET ACS VERSION lt CLICK HERE FIRST Device ID 6 Device IP 197 168 1 5 GET DEVICE ID Get ACS_NOOE_ after setting mew ID ID 8 must be UNUSED by another ACS Modules IP ADDRESS SETUP Set P Address Below Note This version allows changes to the 4th address element ONLI GET DEVICE ID and GET DEVICE IP 192 168 1 5 SET IP ADDRESS values must be populated on the The IP shown above is the default after Page Refreshit page before installing the new ACS The ACTUAL IP address ip in the Address Bar of this page software ACS SOFTWARE INSTALLER F Adobe Acro i Graco a wl PRT FiG 35 Get Device ID and Get Device IP Buttons 3A0006D 35 ACS Software Update 7 Click the button and navigate to the 16J859G C05 or later revision file Click the _Pregram ACS button when the file link is loaded See FIG 36 J ACS ID Assignment Mozilla Firefox Fie Edt yew Hefory fookmarks bol Help ACS ID Assyri Lt gt 192 068 1 5 9080 34 F Most visited Getting Started B Latest Headlines ia Best of the Web Channel Guide Internet Start Merosoft Microsoft Suggested Stes Web Sice Gallery GRACO ACS MODULE SETUP ACS Software Version 1 02 _GET ACS VERSION lt CLICK HERE FIRST
18. al 2 Clear Grand Total This register is set to 0 by the ACS when done 401804 CamMode 1 Cam Mode enabled Pump is compensated to provide constant flow 0 Constant speed mode Motor will run at a constant speed 401805 Modbus Baud Rate 0 19 200 Default 1 38 400 2 57 600 Changes take effect on next power up 401806 AutoCAMoff Determines how the ACS responds to a TDC or Position Sensor failure 1 Run at constant speed determined by Run or Sleep setpoint 0 Stop the pump 401807 High Pressure Alarm Limit x 10 ie 2500 250 psi 401809 AuxOn Aux Relay ON OFF control 1 ON 0 OFF 401810 Low Pressure Alarm Limit x 10 ie 400 40 psi 401811 RemoteReset 1 Reset the ACS to clear alarms ACS will set to 0 when Reset is com plete and the pump will start The Reset pin is edge triggered a low to high will reset the ACS Short the Reset pin to Common then release to reset 12 3A0006D Installation Table 2 ACS Modbus Registers 401800 to 401828 401812 PressAIrmEnable 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 401814 SleepSeipt Setpoint for Sleep Mode x 10 GPM or LPM 401815 RunSetpt Setpoint for Run Mode x 10 GPM or LPM 401816 SleepEnable 1 Sleep Mode is on The Sleep Setpoint i
19. al to the VFD e 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 The VFD drives the pump if the following conditions are met e SECURE DISABLE switch is ON e START STOP switch is ON e There are no VFD or ACS faults NOTE The local control box cannot make flow rate changes Use automation PC VB software or process controller to change the flow rate A control with interface must be used to select a drive speed NOTE See the schematic diagrams on pages 8 10 for wiring details to complete the installation 16 120373 UL CSA Control Box SECURE DISABLE wired to VFD START STOP wired to VFD FAULT RESET wired to ACS Not Used 120991 ATEX Control Box START STOP wired to VFD SECURE DISABLE wired to VFD FAULT RESET wired to ACS Not Used TI10719A FiG 7 Local Control Box 3A0006D Operation Operation Set up a Static IP Address for the Computer NOTE Screen views in this manual are shown using 1 Before connecting your computer to the ACS verify Microsoft Windows XP that Java Version 6 Update 10 Version 7 not com patible is loaded on your computer To verify go to NOTE To run the program Java Version 6 Update 10 Java com using your Internet browser and click on Version 7 not compatible must be loaded on your c
20. and Llser Accounts Center Audio Devices Start Menu a WIBU KEY windows Wireless Firewall Network Set Local Area Connection Status General Support Connection Status Connected Durations 2 days 16 40 51 Speed 100 0 Mbps Activity e Network Connections File Edit View Favorites Tools Advanced Help i Recerved gah N E pa Search gt Folders Address 2 Network Connections Packets 177 850 169 640 LAN or High Speed Internet Network Tasks Local Area Connection Create a new connection ol Connected Properties Disable Change Windows Firewall L lt Intel R PRO LOOO MT Networ settings Fic 9 Control Panel Network Connections and Local Area Connection Status Windows 18 3A0006D c Inthe Local Area Connection Properties win dow FIG 10 scroll to Internet Protocol TCP IP and double click to open the Internet Protocol TCP IP Properties window FIG 11 1 Local Area Connection Properties F Eg General Authentication Connect using EE Intel PRO 1000 MT Network Con This connection uses the following tems Description Transmission Control Protocol lnternet Protocol The default Wide area network protocol that provides communication across diverse interconnected networks C Show icon in notification area when connected Notify me when this connection has limited or no connectivity Pa Pa FFI gt FiG
21. ar of the panel m m mm n m w m m m m m m m m m m m Browse _ Program ACS Sending Line Number R m W m s s s m m sm m w um m m aa m m um m Gs Em m umum sm mas s s sm m m F Adobe Acro D Graco wL WI Fic 33 Standard ACS Module Setup Page 5 Click the GET ACS VERSION FIG 34 button first See J ACS ID Assignment Mozilla Firefox Ble Edt yew Hgoy Bookmarks bok Help ACS ID Ascii gt D 192 168 1 5 9080 GU P A Most visited Getting Started B Latest Headlines a Best of the Web Channel Guide Internet Start Microsoft Merser Suggested Stes Web Shee Gallery GRACO ACS MODULE SETUP ACS Software Version 1 02 GET ACS VERSION CK HERE FIRST l Dank hh ieee DO THIS FIRST Derice ID 6 Device IF 192 168 1 5 GET DEVICE ID GET DEVICE IP LARP TR Seri irm Fic 34 Get ACS Version Button 34 3A0006D ACS Software Update 6 Clickthe GETOEVICEID 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 I ACS ID Assignment Mozilla Firefox Ble Edt yew Hgoy ookmarks Kek Heb ACS ID Acker lt gt 192 168 1 5 9080 3 Most vaged Getting Started B Latest Headlines 5 Best of the Web Channel gle Internet Start Merosot Microsoft Suggested Stes Web Sice Gallery GRACO ACS M
22. claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made 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 LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manu
23. culate the Batch Total use the following formula Batch Total 10000 Batch_CyclesH Batch_CyclesL 401906 AVG_Press Average of last 5 pressure readings 401907 SOFTWARE VERSION 401908 EventFlag Modbus Display only 7 Start Event 401909 RunningFlag 1 The motor is rotating 0 The motor is stopped Status of the AutoSleep input 1 the AutoSleep input is active low Current flow rate x 100 in GPM or LPM 401912 XducerValidFlg 1 Pressure transducer is valid gt 2mA 0 Pressure transducer has failed lt 2mA 401913 to None Not used 401919 401920 ToothStat Status of the Position Sensor The motor must be rotating for the system to determine the validity of the position sensor 1 Valid the ACS is receiving Position Sensor pulses 0 Failed the ACS is not receiving Position Sensor pulses 401921 PLC_ID Modbus node number assigned to this ACS 401922 ResetStat Status of the ACS Reset input pin 1 the Reset pin is active low 401923 TDCStat Status of the TDC Top Dead Center Sensor The motor must be rotating for the system to determine the validity of the TDC Sensor 1 Valid the ACS is receiving TDC Sensor pulses 0 Failed the ACS is not receiving TDC Sensor pulses 14 3A0006D Installation Table 3 ACS Modbus Registers 401900 to 401950 401924 HeartBeat Alternately set to 1 and 0 every second This indicates that the ACS pro gram is operating 401925 DriveCmdHz Current d
24. dicators 3A0006D Alarms Screen See FIG 30 The Alarms screen logs the date time and description of each alarm Fic 30 ACS Alarms Screen 3A0006D ES PumpO IP 192 168 1 5 Date MRD DT YYY Rn 6 2011 B11 5 2011 Sn 5 2011 Sn 5 2011 Sn 5 2011 6115 2011 Sn 5 2011 6512011 615 2011 Sn 5 2011 Sn 5 2011 6115 2011 61 5 2011 6115 2011 Sn 5 2011 65 2011 Sn 5 2011 6115 2011 Sn 5 2011 Sn 5 2011 Sn 5 2011 6115 2011 Sn 512011 6152011 Operation See page 41 for descriptions and explanations of each alarm warning Alarm Description Start Event Stop Event ducer Fail Start Event Stop Evert Start Event Stop Event Start Event Stop Evert Start Event Stop Evert Start Event Stop Ewent start Event Stop Event Start Event Stop Event start Event Stop Event Start Event Stop Event Start Event Stop Ewent Start Event Click to refresh the screen 31 ACS Software Update ACS Software Update This process is required to load files to the Graco ACS 1 Connect the ACS module Ethernet port to the module for an upgrade of the ACS application software PC Laptop using an Ethernet cable The process allows update of application software through the Ethernet port NOTE Some laptops will allow connections with or with out a crossover cable A standard Ethernet patch cord It is critical that the directions be followed in the correct should work but a crossover cable may be requi
25. ed and optional system components See Fic 6 for a detailed schematic of VFD Barrier and Start Stop connections Inputs and Outputs FIG 3 shows the ACS Module input and output terminal block See also FIG 4 Fic 5 and System Diagnostic Indicators page 30 K RO es ED Oe On INPUTS Indicators and Pushbutton FiG 3 shows the ACS Module indicators and POWER INTERRUPT pushbutton See also FIG 4 and FIG 5 Table 1 ACS Module Indicators and Pushbutton Indicator or Button POWER ON indicator DRIVE ENABLED indicator Condition The ACS is powered and the pump is running Turns on if the ACS is sending an analog drive command and the drive enabled relay is closed POWER INTERRUPT pushbutton Press momentarily to interrupt power for sys tem reboot Power is restored when released POWER 24VDC GRACO Indicators see Table Power Interrupt Pushbutton see Table 1 FiG 3 ACS Module Indicators and Input Output Terminals 3A0006D Installation Critical Item Checklist L Wire according to FIG 4 on page 8 and FIG 5 on page 9 Use Belden 8777 cable or equivalent It is impor tant to use multiconductor cable with 3 individu ally shielded pairs 1 Ferrite 15D906 must be installed on pressure transducer wires L Do not place signal wires in the same conduit as AC Power wires For example the TDC Position sensor wires should
26. er Home 2010 Graco Inc Fic 12 ACS Module Setup Screen 20 3A0006D 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 num bered 0 49 in the system Click on a Pump Name key to open the Run screen for that pump FIG 14 shows the Run screen If communication is interrupted due to a loose cable or broken wire first correct the problem then click on to re establish communication Click on a Pump Name key to open the Run screen for that pump see page 23 Operation 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 NOTE Open the program Start gt All Programs gt Gra coACS gt GracoACS The program will search for all pumps in the ACS system and populate the ACS Sys tem Status Screen See FIG 13 NOTE This program does not require the PC be config ured with Static IP Address Configured through web browser see ES Graco E Flo Pump Status Pump Mame i iT m m i aam 1 J Pumpi Pumpi Pump Pump3 preg Pump5 _ Purine Purmer _ Purine Pumna Pumpi U Pump11 Purripi 2 Pump13 Pump 4 Pumps Pump B emme Pumpi I Pump Pump 2 Pumped Flo U U U U U
27. eve 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 The Graco ACS control module software mimics the effect of a camshaft constantly adjusting motor speed to keep steady fluid flow and achieve minimal pressure variation The output shaft of the gearbox and the connecting rods experience the electrical control module simulating the function of a camshaft by speeding up when the pressure drops pump lower is at a changeover and slowing down when pressure increases both lowers are pumping The ACS module provides an analog drive signal to the VFD Use one ACS module for each E Flo pump The ACS module can be controlled by a local control box mounted in the hazardous area or via communication protocol such as modbus B GR Sr TDC and Position Sensors behind cover a LOS d Bey FIY U LEN FP tn y Ar FP z 7 N ti8317c ti8321a FiG 1 Electric Circulation Pump FIG 2 Cutaway Showing Offset Stroke Positions 3A0006D 5 Installation Installation All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations FIG 3 shows the ACS panel See FIG 4 and FIG 5 for schematic diagrams showing wiring connection points of all requir
28. evious 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 Power ON the ACS Module Hold the RESET INPUT pins 7 8 of input con nector on ACS module for 5 to 10 seconds then remove the RESET INPUT with power still applied od oo Window will clear automatically EO mee se e The IP Address has now been changed to 192 168 1 5 but the change will not take affect until power is cycled again e Cycle power to the ACS Module OFF then ON to apply the change NOTE The white power button on the ACS Module can be used to cycle power during this process It is not nec essary to unplug the 24 Vdc supply 3A0006D 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 Failure to do so will result in Pressure Sensor Calibration Trip nui sance trips or system malfunctions 2 Pump Lower Size Selection NOTE If the pump lowers are changed to a different size after purchase the pla
29. f the maximum flow setpoint exceeds the pump s capability Minimum Flow Warning Lights if the flow rate in pressure mode is less than 80 percent of the Run Setpoint The system reverts to flow mode at the Run Setpoint The system will return to pressure mode once the pres sure has dropped back below 5 of the pressure set point for two cycles Autosleep Input Lights if a Sleep Enable input is received from the PLC Closes the Auxiliary Relay Reset Input Lights if a Reset Fault input is received from the PLC TDC Sensor Status of the TDC Top Dead Center Sensor The motor must be rotating for the system to detect the TDC Sensor Position Sensor Status of the Position Sensor The motor must be rotat ing for the system to detect the Position Sensor NOTE TDC and position sensor indicators will both be lit when the motor is moving and the ACS module is receiving proper signals Auxiliary Relay Lights if Auxiliary Relay is turned on page 27 Drive Enable Relay Lights if Drive Enable Relay is turned on 30 Transducer Lights if the system detects a pressure transducer is present ACS ID Automatic input Modbus node number Not editable ACS Software Revision Automatic input Not editable PC Software Revision Automatic input Not editable EEE as Za oes Hoey cee sia atan Drive Enable Relay ACS IDF ACS Software Rev PC Software Rev 1 071 004 FiG 29 System Diagnostic In
30. facturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make change
31. g NO S3HIA Z O SNOCHYVZVH NON ONINNNY SOY INdLNO WHVTv LUE L dO EL ZL YO ZU LL LAdLNO ASVHd dVNS NOILOAYIG HOLOW 3SNVHO OL NVd LV SNIMOO71 NAHM MOO SI NOILOYIG HOLOW GSYINOAY JHL NOILOAUYIC 01210295 V NI dNNd AHL NNY OL 0 HO c0 dINNd JHL ONILYVLS ANY ONIiddOLS HOS SI Z0 STIVNIWY AL SEN aoe vVOLNZd8d VZz G4A 3H1 S318VvSiq LSNF HIMOd LOANNOOSIG I R NAY LON S3Od SIHL 1n8 dO1S 3 NY SMM HOLIAS F 1dNY X 2 318vsiq SYNOAS IHL OL LOANNOO v0 ANY L0 STVNINH3L NI OV 3SvHd GO O O NOILISOd SNS OOOOO NI 29 LSNW C AOTAN HOLINS O I TVN IS JMH SO TVNV HOLIAS da31 nOti LaNtidH1I3 WNOILdO H3MOd OAAPZ SINOD S8rSH aNY SSINGOW SOV ATdILINW OL 089V9 WOYS 89V9 WOYSs NINOI YO vOS6 N3q 138 Q1aIHS HLIM ATEVO YHOLONGNOD 8 NO j uaMoOd OS 6b SL ZL QL Sh PL Gh ZL UL ODVE OCAYS YSMOd TUDIA DOTVNY SLAGLNO co e _ k E ol z are I 1 I TIVLAG SNIHIA Di 1 JINON sov 2 J Fic 4 System Schematic Diagram Non Hazardous Area 3A0006D Installation A LltdV 19 tdOd O 1H3 QdA AHL INOtid ANY OL NMOHS LON 29Y SHOLSINHJHL Od ONIYIM SNTd SNIHIAA 3SVHd ALON HdOSN3S NOILISOd dOSN3S 9AL H2On0SNY UL AYNSSAYd LINDUID SI dOSN3S YAWVN OGL 13s3u dOLS LHYLS LINGNOO 4OOud aavsid NOISO1dX3 3uno3s TIV13G ONIYIM NOILVLS NOI lVtI3dO LINGNOO 3JOOtd NOISO 1dX3 129520 dOLS LYVLS 318VvSIq AYNOAS NOILV
32. mp Language English FiG 18 Units Drop down Menu 25 Operation Select Control Mode Click on the button to view the drop down menu Select the desired control mode e Flow The pump will run at a constant flow rate e 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 NOTE The Hz command will fluctuate in pressure mode or in flow mode if cam is enabled Kiodel E Flo 4000 Units English Control ode Pressure Setpoint Purnp Mame Pump Language English FiG 19 Control Mode Drop down Menu Select Pressure Setpoint Click on the button to raise or lower the setpoint as desired Set Unique Pump Name Input a unique name for each pump monitored by the ACS The name may have up to 20 characters 26 Select Language Click on the button to view the drop down menu Select the desired language e English e French e German e Chinese e Japanese e Korean e Spanish e ltalian e Polish e Russian e Swedish Mannie E EIp 4000 Units English Control Made Flow Pressure Setpoint Pump Mame Language Auto Decrement Aux Relay On CAM Mode Sensor Fault Ou err Transducer Fault OV Polska Pressure TransducaParrcum FiG 20 Language Drop down Menu 3A0006D Select System Features
33. mp motor e Stopped ACS module receiving position pulses e Motor Running ACS module not receiving position pulses 3A0006D Config Button Click on the Config key to open the Configuration screen See page 24 Pump Name ACS IP Address Date and Time i Em PumpO IP 192 168 1 5 6 24 2011 8 47 22 CHM Fio hdotor Crd Hz Pressure HDS Fault Display None Reset Fault Key FiG 14 Run Screen 3A0006D Stop Key Click to open Operation Alarms Button Click on the Alarms key to open the Alarms screen See page 31 Pump Performance Pump Setpoints Data Pressure Setpoint PSI 250 Run Setpoint Sleep Setpoint Run Key Motor Status Display Click to open Configuration Alarm screen screen page 24 page 31 23 Operation Configuration Screen See FIG 15 Use this screen to set the configuration for each pump Pump Parameters Eel PumpO IP 192 168 1 5 9 2 2011 9 40 1 see page 25 Units Metric Flow v Pressure Setpoint 4 6 lt BAR English v Control Mode Pump Mame System Features see page 27 Language Auto Decrement C Aux Relay Gn CAM Mode Sensor Fault Override Transducer Fault Override Pressure Transducer Enable C Sleep Enable Run Setpoint Sleep Setpoint Run and Sleep Setpoints see page 27 Reset Totals see page 29 Fic 15 Configuration Screen 24 H Set Clock j
34. om Do Have Java for further information puter This is a free download 2 After verifying that Java is loaded on the computer connect the computer directly to the Ethernet Port on the bottom of the ACS module using a CAT5 Ethernet crossover cable See FIG 8 ACS Module CAT5 Ethernet Crossover Cable ACS Module Ethernet Port Computer T117645a T117556a FIG 8 Connect the Computer to the ACS Module 3A0006D 17 Operation 3 Before running the software you must manually b See FIG 9 Double click on Network Connec assign an IP address to your computer tions Double click on Local Area Connection to open the Local Area Connection Status window a On your computer click on the Start button Click on Properties to open the Local Area Con nection Properties window See FIG 10 ts Start to open the menu then click on Control Panel br control Panel Control Panel File Edit View Favorites Tools Help Q Back wi PP Search Key Folders ddress J Control Panel See Also amp lt w Q 7 amp Accessibility Add Hardware Add or Administrative Automatic Date and Time Display Help and Support Options Remoy Tools Updates gt S 9 H Game Intel Internet Java Keyboard ontrollers Graphics Options A b 3 Network Pine and Power Options printers and Regionaland Scanners and Connections odem Faxes Language Cameras e Pa s Security Sounds and Speech System Taskbar
35. on is turned off disabled before performing step 4 4 D In a web browser enter http 192 168 1 5 9080 Press Enter The ACS Module Setup Screen appears See FIG 12 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 i ACS ID Assignment lt 192 168 1 5 9080 GRACO ACS MODULE SETUP ACS Software Version GET ACS VERSION GET ACS VERSION lt CLICK HERE FIRST Device ID Device IP GET DEVICE ID GET DEVICE IP NODE ID SETUP Enter New ID SET NODE Get ACS NODE Z after setting new ID ID must be UNUSED by another ACS Modules IP ADDRESS SETUP Set IP Address Below able field then click SET IP ADDRESS to enter Set the Node ID number only if the ACS is con nected to a Graco Gateway The ID number must be unused by other ACS modules Click on GET ACS NODE to access the default Node ID number which will then appear following Device ID Type a new number in the Enter New ID field then click SET NODE to enter Note This version allows changes to the 4th address element ONLY 192 168 1 SET IP ADDRESS The IP shown above is the default after Page Refresh The ACTUAL IP address is in the Address Bar of this page ACS SOFTWARE INSTALLER BACK Web Serv
36. pm or Ipm as selected on the Configuration screen see page 25 Motor Command Hz The speed command in Motor VFD frequency 4 20mA scaled 0 80 Hz This is not the frequency output by the VFD Fluid Pressure The fluid pressure is displayed in psi or bar as selected on the Configuration screen see page 25 Pump Setpoints Run Setpoint The Run Setpoint is displayed as set on the Configura tion screen see page 27 Sleep Setpoint The Sleep Setpoint is displayed as set on the Configu ration screen see page 27 22 Pressure Setpoint The Pressure Setpoint is displayed as set on the Con figuration screen see page 26 Fault Status The screen displays if there is a fault None High Pressure Low Pressure Xducer Transducer Fail Pressure Sensor Auto Xducer Fail MIN FLOW Warning Position Error Auto Cam Off Position Auto Cam Activated No TDC Signal Max Flow Auto Cam Off TDC Start Event Stop Event NOTE See page 41 for alarm descriptions and trouble shooting Click on the Reset key to clear NOTE The pump starts after a Reset Run Button Click on the Run key to start the pump Stop Button Click on the Stop key to stop the pump NOTE The Run Stop buttons function as enable dis able active management is not necessary This can be left in Run and the pump motor controlled from a physi cal start stop switch connected to VFD Motor Status The screen displays the status of the pu
37. red order and with detail depending on how your PC Laptop is wired Required data and equipment 2 Set the Static IP Address on the PC Laptop Ensure the PC Laptop network settings are configured for a The Graco Firmware file will be loaded through the static IP Address The PC Laptop should be set to web browser It will be 16J859G CO5 or a file of the same network settings as the ACS module The this format with a xxx CO5 extension of a later ver default ACS module IP is 192 168 1 5 Therefore sion This software is available at www graco com set the static IP of the PC Laptop to 192 168 1 XXX where XXX 200 as an example See FIG 31 e Any PC Laptop with an Ethernet port and Mozilla Firefox web browser program preloaded version 3 0 or higher Use only Mozilla Firefox Internet Explorer IE will not work properly Metwork Connections Back lt j Search J Folders 7 7 HT kirest Q Network Connections Bisnis Type Shakti Daca Hor Ep lets 2567 LM Gapatet Hebasyzk Co T Interne Protocol TOPAP Properties Then conection une the zeer tems w W Poe Protocol BEEE BZ Ie vo 4 w WU hehe Medor Diras s W interme Protocol TCP AP Tou canga IF teigi acid Sra aly pour retek popes the capatity Others pou need to ack pour network alr ates for the appropnate IP zeir O UEZ an an IP sidder sumac alla Ce Usp tisa ldr F ales IF ahe 182 The 1 AX Descr T usna
38. rive speed command x 10 ie 0 to 800 0 to 80 Hz 401926 Current_Alarm Represent the current alarm code Alarm Code No Description 0 No alarm No current alarm event 1 QOVERPRESS System stopped due to overpressure 2 UNDERPRESS System stopped due to underpressure 3 Xducer Fail Pressure Sensor failure pump stops 4 NOTDC STALL TDC failure pump stops 5 MAXFLOW Attempted to drive gt 80 Hz WARNING 6 AUTO CAM TDC Sensor failure Pump continues to run in con OFF TDC stant soeed mode The CAM function is disabled 7 START EVENT Logged only 8 STOPEVENT Logged only 9 AutoXducerFail Pressure Sensor failure Pump continues to run without pressure monitoring 10 MINFLOW Minimum Flow Warning see page 30 11 Position Error Position sensor failure pump stops 12 AUTO CAM Pump continues to run in constant speed mode OFF Position The CAM function is disabled 13 AUTO CAM CAM automatically reactivated sensor signal ACTIVATED found 401927 MaxFloFlg Set when ACS attempts to drive the motor at more than 80 Hz Cleared after two pump cycles 401928 AuxOutStat Status of the AuxOut Relay 1 Relay closed O Relay open 401929 DrvEnableRlyStat Status of the Drive Enable Relay 1 Relay closed O Relay open 401931 AnalogIN2 Spare Input Pins 3 and 4 i mil Value 0 4095 represents 0 20 mA current 401946 3A0006D 15 ACS Control Mode ACS Control Mode The ACS module provides an analog drive sign
39. rned off Click on the gt button to raise or lower the setpoints as desired These values are expressed in gpm or Ipm There are two setpoint fields e Run Setpoint sets the rate of the pump when it exits Sleep mode and enters Run mode e Sleep Setpoint sets the rate of the pump during Sleep mode Sleep Enable Run Setpoint Sleep Setpoint FIG 22 Sleep Settings 27 Operation Calibrate the Transducer NOTE Only a 4 20 mA output 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 For a non Graco transducer refer to the manufacturer s label or data sheet ti17606a Fic 23 Calibration Label Location Enter the transducer calibration values where shown in ae FIG 24 using the button to raise or lower the set point as desired After the values are entered the ACS will perform the calibration Cal High PSl Cal Low PSI Cal High mA Cal Low mA Fic 24 Calibration Values 28 Set the Clock On the Configuration screen click on Set Clock to access the clock screen see FIG 25 There are two methods to set the clock ae e To input the values yourself use the gt buttons e To synchronize the ACS clock with your PC click on Sync Clock to PC All values will be loaded from the PC and the window will close EE PumpO IP 192 168
40. s at any time without notice Original instructions This manual contains English MM 3A0006 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES e P O BOX 1441 MINNEAPOLIS MN 55440 1441 lt USA Copyright 2011 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revision D April 2014
41. s used as the target flow rate 0 Sleep off The Run Setpoint is used as the target flow rate Sleep can also be enable by the external AutoSleep input pin Sleep Mode is enabled when either control is active 401817 PressSetPt Pressure Mode setpoint x 10 This is the target pressure for Pressure Control Mode 401818 Cntrl_Mode 0 Flow Control Maintains a constant flow rate Flow rate is either Sleep or Run Setpoint depending on 1816_SleepEnable input 1 Pressure Control Maintains a constant pressure defined by 401817_PressSetPt 401820 AutoDecrement 1 Enabled automatically minimizes the flow rate in pressure mode allowing the BPR to close See Auto Decrement page 27 401821 RunStop 1 Run 0 Stop Power up or Reset will set RunStop to 1 401828 AutoXducerFail Determines how the ACS responds to a pressure transducer failure 1 Run at constant flow rate determined by Run or Sleep setpoint 0 Stop the pump 3A0006D 13 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 Pump cycles per minute x 100 401903 GT_CyclesH Grand Total cycles high word To calculate the Grand Total use the following formula Grand Total 10000 GT_CyclesH GT_CyclesL 401904 Batch_CyclesL Batch Total cycles low word 401905 Batch_CyclesH Batch Total cycles high word To cal
42. swa en Cantal Paoi cs cL 5rd re Protacal wade Sra reimo potoci Ghat Cercle com acre drer bp mierconne cied pahaku Gubri mast Chel all gammy T Shew se ri hc etr wea elect crre heed Holly me when thes conmecton har lieved o S Lee the lolya DNS server l r Prefered DHS server Abena DHS pemer FIG 31 Setting the Static IP Address on a PC or Laptop 32 preu E arw d Modem Dusruorrusched ThinkPad Modern Adapter h Spod inter Not connected Intel WF Link 5100 AGN Ty Sheed Inter Cometa rek B 1 SE TD Gabi Netedet Connection _ mis YUN Adapter Phone or Hat Akben FAF 01441 Sam Sign Symen pai KGT La 3A0006D FIG 32 Z 192 168 1 5 9080 GRACO ACS MODULE SETUP ACS Software Version lt CLICK HERE FIRST Device ID Device IP GET DEVICE ID GET DEVICE IP NODE ID SETUP Enter New ID SET NODE Get ACS_NODE_ after setting new ID ID must be UNUSED by another ACS Modules IP ADDRESS SETUP Set IP Address Below Note This version allows changes to the 4th address element ONLY 192 168 1 SET IP ADDRESS The IP shown above is the default after Page Refresh The ACTUAL IP address is in the Address Bar of this page ACS SOFTWARE INSTALLER BACK Web Server Home 2010 Graco Inc Fic 32 Digital Signature Verification Window 3A0006D When the Digital Signature Verification window appears click Run Be sure tha
43. t the Always trust content from this publisher box is not selected See ACS Software Update Sees lt a eae Click Run The application s digital signature cant be verified Do you want to run the application Name JavaSocketBridge Publisher NOT VERIFIED Stephen Ware From http 192 168 1 5 9080 More Information digital signature cannot be verified by a trusted source Only you trust the origin of the application Do Not Select 33 ACS Software Update 4 Open Mozilla Firefox web browser In the address bar enter http 192 168 1 5 9080 See FIG 33 acs D Astiporment Marilla Fir faxw Bile Edt yew Hgoy Bosimaks pos Help ATS ID Asaga gt 192 168 15 9060 Mest Vieted Getting Started mj Lat Aa Best dd the Web ChannelGuide Internet Start Merosoft Merosoft Suggested Stes Web Sice Gallery ACS Software Version 1 02 Device ID 6 Device IP 192 168 1 5 GET DEVICE ID GET DEViCE IF Enter NODE ID SETUP http 192 168 1 5 9080 Enter Mear ID SET HODE Get ACS_NOOCE_ after s IDI i i ID must be UNUSED by anther ACS Modules Use this page for configuring the ACS module after the latest firm arto purdi Ware upgrade to 1 02 Note This w ergion allows Charmes to the 4th address elament OP V1 192 168 1 s SET IP ADORESS The hown above 6 the default after Page Reseo The ACTUAL IP address 6 m the Address B
44. te information is no longer valid 3 Unit Selection The defaults are psi and gpm Table 4 Measurement Unit Summary 3A0006D 4 User VFD Setup NOTE Each VFD brand will have varying setup param eters ACS and E Flo performance is optimized by the following key VFD settings e analog input scaling e 4mA 0 zero Hz e 20 mA 80 Hz e Acceleration rate 1 0 sec for full range 0 80 Hz e Deceleration rate 0 5 sec for full range 0 80 Hz NOTE If the ACS is used with an E Flo 1500 pump and a 3 HP motor activating the VFD slip compensation fea ture may reduce motor heat and improve performance under certain conditions 5 E Flo Motor Specific Parameters Verify that the parameters entered in the VFD match the motor parameters rated voltage maximum rated cur rent limit rated frequency rated speed in rpm Other setting selections will be required to allow for the recognition of an analog speed command and motor ID match and limits Contact Graco for motor information and or a list of locally supplied pre approved motors 39 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 Dis able input See FIG 4 FiG 6 on pages 8 10 for further information Back Pressure Regulator
45. than the entered low pressure trip point This alarm is dis abled for 1 minute after the pump starts to prevent pre mature alarms Xducer Fail Max Flow The requested flow rate is beyond the pump s capability Min Flow The flow rate is too low for the Run Set point Auto Cam Off TDC Posi tion Table 7 Faults and Diagnostic Procedures Check High Pressure Alarm setting Verify that system desired operational pres sure is lower then High Pressure Alarm setting Check for flow restrictions closed valves unexpected restrictions Check pump fluid section for proper operation piston seals ball checks Refer to pump maintenance manual for additional information Check Low Pressure Alarm setting Verify that system desired operational pres sure is higher then Low Pressure Alarm setting Check fluid level Low fluid level will cause system to run at low pressure Check fluid supply to the pump Check pump fluid section for proper operation piston seals ball checks Refer to pump maintenance manual for additional information Loss of pressure transducer analog signal cause by wiring problem pressure transducer failure circuit board failure EMF noise on the control cable Reduce the requested flow rate A 20 mA analog drive signal is the maximum NOTE This trip is a Warning and will not shut off the pump Decrease the back pressure regulator pressure or increase the Pressure Setpoint NOT
46. upply for the pump sensor circuit See manual 311608 This assem bly includes the following required power supply and barriers which are also available separately 121314 Power Supply required 24 TES 2 A DIN rail mount E l TI15662a 16A630 TDC and Position Sensor Barrier 2 channel required E a e 16A633 Transducer Barrier 1 channel required TI15663a CAT5 Ethernet Cables 121994 1 ft 0 305 m 121998 25 ft 7 6 m 121999 50 ft 15 2 m 15V842 100 ft 30 5 m 15V843 200 ft 61 0 m Optional Components Optional ACS components can be ordered through your Graco Distributor 15V342 Ethernet Switch Enables connection of ACS module to multiple network components through an Ethernet l fi TI15660a Local I O Box 120373 UL CSA 120991 ATEX Allows the operator to control the E Flo locally at the pump when performing maintenance or troubleshooting See page 12 Includes the following features e secure disable switch e start stop switch fault reset J o ox oF g w 0120 0000 lt RRRNINNNN 3A0006D 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 achi
47. ut 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 The light should be normally on and it should be off for only short period of time when position is reached Stall Relieve system pressure Check lowers slider cylinders and output shaft with connecting rods for visible damage If no damage is visible check for excessive heat which is a sign of fric tion Check the system control circuit wiring Check that the motor is turning If not check motor wiring Disconnect lowers and try running just the motor and gearbox 3A0006D Technical Data Technical Data Inputs FOWE Sema EE tonto tego ntaweedwde Sees 20 30 Vdc 200mA reverse polarity protected Analog inputs 2 inputs for 4 20mA current loop sensing Inputs pro tected from direct application of 24 Vdc RIs Tr RTE z u cee tu suu anl dee eda Sx 4 inputs TDC Position Sensor AutoSleep and Reset Digital inputs are 24V logic level NPN Outputs S EE IMA eee grees oe See oe qia KS S w 2 channels adjustable offset and span Digital outputs 2 open contact normally open relay outputs 24V 1A used for BPR control and Drive Enable Communications a 1 Ethernet port and 1 RS485 port Ambient Conditions Operating temperature range 0 50 C 32 121 F Operating R midily u uy l
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