Graco 3A0006EN-D User Manual
Instructions
24H372
3A0006D
ACS Module
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.
EN
ti17553a
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 . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . 6
Indicators and Pushbutton . . . . . . . . . . . . . . . . . 6
Critical Item Checklist . . . . . . . . . . . . . . . . . . . . . 7
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . 8
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ground the ACS Control Module . . . . . . . . . . . 11
ACS Modbus Registers . . . . . . . . . . . . . . . . . . . 12
ACS Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Set up a Static IP Address for the Computer . . . 17
ACS System Status Screen . . . . . . . . . . . . . . . . 21
Run Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Configuration Screen . . . . . . . . . . . . . . . . . . . . . 24
Alarms Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ACS Software Update . . . . . . . . . . . . . . . . . . . . . . 32
ACS System Setup Checklist . . . . . . . . . . . . . . . . 39
ACS Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Drive Active (System ON) Output . . . . . . . . . . . 40
Back Pressure Regulator (BPR) Production/Sleep
Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Flow Rate Monitoring . . . . . . . . . . . . . . . . . . . . . 40
Operational Envelope Limit . . . . . . . . . . . . . . . . 40
Pressure Limits . . . . . . . . . . . . . . . . . . . . . . . . . 40
Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . 41
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 44
Related Manuals
Manual Description
311592 E-Flo Installation Manual
311593 E-Flo Operation Manual
311594 E-Flo Repair-Parts Manual
311603 24J305 Sensor Circuit Option
311690 4-Ball Lowers with open wet-cup
3A0539 4-Ball Lowers with enclosed wet-cup
2 3A0006D
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.
WARNING
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 circuit 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 supply for the
pump sensor circuit. See manual 311608. This assembly includes the following required power supply and
barriers, which are also available separately:
121314 Power Supply (required)
24 Vdc, 2 A. DIN rail mount.
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.
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:
• secure disable switch
• start/stop switch
• fault reset
TI15662a
16A630 TDC and Position Sensor Barrier
(2 channel) [required]
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)
4 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 achieve consistent flow from the pump assembly. See F
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).
IG
. 2.
B
TDC and
Position
Sensors
(behind
cover)
FP
F
IG
. 1. Electric Circulation Pump
GR
PT
FP
ti8317c
ti8321a
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 required and optional system components.
Indicators and Pushbutton
FIG. 3 shows the ACS Module indicators and POWER
INTERRUPT pushbutton. See also F
Table 1: ACS Module Indicators and Pushbutton
Indicator or
Button Color Condition
POWER ON
indicator
Solid
Green
IG
. 4 and FIG. 5.
The ACS is powered and
the pump is running.
See F
IG
. 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 F
Indicators, page 30.
IG
. 4, FIG. 5, and System Diagnostic
DRIVE
ENABLED
indicator
POWER
INTERRUPT
pushbutton
Solid
Red
n/a Press momentarily to
Turns on if the ACS is
sending an analog drive
command and the drive
enabled relay is closed.
interrupt power, for system reboot.
Power is restored when
released.
Indicators;
see Table
Power
Interrupt
Pushbutton;
see Table 1
FIG. 3. ACS Module Indicators and Input/Output Terminals
6 3A0006D
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 impor-
❑
tant 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.
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)
• Deceleration rate = 0.5 second (for full
range)-80 Hz)
Installation
3A0006D 7
Installation
Schematic Diagrams
POS - BLK
POS + WHT
TDC - J2 - 4 BLK
TDC + J2 - 3 GRN
12345612345
NON-HAZARDOUS
BARRIER
WIRING DETAIL
SENSOR BARRIER
TDC AND POSITION
ALL SWITCHES "ON"
(16A630)
POSITION / POSITION I
+ J3 - 1 RED
- J3 - 2 BLK
6
(16A633)
4-20ma BARRIER
PRESSURE TRANSDUCER
TDC AND POSITION
SENSOR BARRIER
4-20ma BARRIER
PRESSURE TRANSDUCER
ACS CONTROL HANDLES:
- TDC INPUT
- 4 TO 20ma PRESSURE FEEDBACK
(0 - 500 PSI)
- CALCULATES POSITION (DEG)
- DRIVE ANALOG OUT RELATIVE TO
REQUIRED SPEED PER DEGREE
B = SLEEP MODE INPUT FROM PLC
OR FROM COMMUNICATIONS/TOUCH
SCREEN
ALARM INTERUPT OF START/STOP INPUT
RESET TO +
ACS MODULE -
TO ACS SWITCH
01 STOP INPUT/
SECURE DISABLE
02 RUN/FWD
03 RUN/REV
04 COM
05 DIGITAL IN 1
02 04 05 060301
11 13 16151412
06 DIGITAL IN 2
11 +24VDC
12 +10VDC
13 0 - 10VDC IN
14 ANALOG COM
15 4-20ma IN
16 RS485 SHLD
ACS ANALOG VFD +
ACS ANALOG VFD -
7891314157891314
TDC+
POS+
TDC- / POS-
TERMINAL 8
2 WIRES ON
ACS MODULE
WIRING DETAIL
FROM 16A630
9
8
FROM VFD
14
15
24 VDC
COMMON
15
+
-
24 VDC
COMMON
ACS MODULE
8 CONDUCTOR CABLE
WITH SHIELD
BELDEN #9504 OR EQUIV.
RS485 COMS / 24VDC POWER
8
7
7
8
FROM 16A630
TO MULTIPLE ACS MODULES AND
FROM 16A633
OPTIONAL EITHERNET ROUTER/SWITCH
RESET
ALARM OUTPUT
(ACS RUNNING)
ANALOG DRIVE SIGNAL
SECURE
DISABLE
EXAMPLE:
ALLEN BRADLEY VFD
W/T3V/T2U/T1S/L2
LINE LOAD
R/L1 T/L3
I/O SWITCH
MUST BE IN
SNK POSITION
ENSURE
THERMISTOR
WIRES ARE
CONNECTED
FROM MOTOR
WIRING DETAIL
EFLO MOTOR
TERMINALS 01 AND 04 CONNECT TO THE SECURE DISABLE
SWITCH. (LIKE AN E-STOP BUT THIS DOES NOT
DISCONNECT POWER, JUST DISABLES THE VFD.) TERMINALS 02 IS FOR STOPPING AND STARTING THE PUMP.
02 OR 03 TO RUN THE PUMP IN A SPECIFIC DIRECTION.
THE REQUIRED MOTOR DIRCTION IS CCW WHEN LOOKING
AT FAN. TO CHANGE MOTOR DIRECTION, SWAP 3 PHASE
OUTPUT T1/T2 OR T2/T3 OR T3/T1.
3 PHASE AC IN
EXAMPLE:
ALLEN BRADLEY VFD
(22A-D8P7N104)
CONNECTION DETAILS
FIG. 4. System Schematic Diagram, Non-Hazardous Area
8 3A0006D
16J588
POSITION
SENSOR
-BLU
+BRN
TDC NAMUR
SENSOR
1 +BRN
2 -BLU
J2
3
4
PRESSURE
1 RED
2 GRN
3 WHT
J1
123
J3
TRANSDUCER
4 BLK
5
E-FLO JUNCTION BOX
IS CIRCUIT PRESSURE TRANSDUCER
FERRITE
(16G496)
TDC SENSOR
POSITION SENSOR
E-FLO
NOTE: 3 PHASE WIRING PLUS WIRING
FOR THERMISTORS ARE NOT SHOWN TO
AND FROM THE VFD/EFLO FOR CLARITY
Installation
E-FLO PUMP JUNCTION BOX
HAZARDOUS
3 PAIRS INDIVIDUALLY
WIRING DETAIL
(SEE MANUAL FOR DETAILS)
BELDEN 8777 OR EQUIV
WITH FERRITE (123375)
SHIELDED CABLE
STATION
OPERATOR
SECURE / DISABLE
START / STOP
RESET
OPERATION STATION
EXPLOSION PROOF
CONDUIT
WIRING DETAIL
SECURE
DISABLE
EXPLOSION
PROOF CONDUIT
RESET
START/STOP
FIG. 5. System Schematic Diagram, Hazardous Area
3A0006D 9
Installation
PRESSURE
ETHERNET COMS
MONITOR
PLC CONTROL /
OPTIONAL ETHERNET ROUTER/SWITCH
E-FLO #N
PRESSURE / TDC + POS
STATION
OPERATOR
E-FLO #3
PRESSURE / TDC + POS
STATION
OPERATOR
TDC/POS
BARRIERS #N
DISABLE
SECURE START / STOP / RESET
3 PHASE POWER
PRESSURE
TDC/POS
BARRIERS #3
DISABLE
SECURE START / STOP / RESET
3 PHASE POWER
RESET
SIGNAL
ANALOG DRIVE
RESET
SIGNAL
ANALOG DRIVE
ACS MODULE #N
VFD #N
GENERIC
ACS MODULE #3
VFD #3
GENERIC
PRESSURE
E-FLO #2
PRESSURE / TDC + POS
STATION
OPERATOR
E-FLO #1
PRESSURE / TDC + POS
STATION
OPERATOR
HAZARDOUS
NON-HAZARDOUS
TDC/POS
BARRIERS #2
DISABLE
SECURE START / STOP / RESET
3 PHASE POWER
PRESSURE
TDC/POS
BARRIERS #1
DISABLE
SECURE START / STOP / RESET
3 PHASE POWER
RESET
SIGNAL
ANALOG DRIVE
RESET
SIGNAL
ANALOG DRIVE
ACS MODULE #2
VFD #2
GENERIC
ACS MODULE #1
VFD #1
GENERIC
24 VDC
FIG. 6: Detailed Schematic, Connections to VFD
10 3A0006D
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.
Installation
The ACS Module DIN rail bracket may be reversed if
desired, to accommodate installation requirements.
Remove the screws, turn the bracket 180°, and reattach.
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
Register No. Register Name
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.
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
Description
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 HipressLim High Pressure Alarm Limit x 10; ie, 2500 = 250 psi.
401808 None Not used.
401809 AuxOn Aux Relay ON/OFF control.
1 = ON
0 = OFF
401810 LowPressLim 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
Table 2: ACS Modbus Registers 401800 to 401828
Installation
Register No. Register Name
401812 PressAlrmEnable
0 = No alarms.
Description
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 SleepSetpt 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 is 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.
401822 GaugePresH High Gauge Pressure entered during calibration, PSI only
401823 GaugePresL Low Gauge Pressure entered during calibration, PSI only
401824 ADmAHigh High pressure CAL, Transducer current xx.x mA.
401825 ADmAHigh Low pressure CAL, Transducer current xx.x mA.
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
Register No. Register Name
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.
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 calculate the Batch Total, use the following formula:
Batch Total = (10000 * Batch_CyclesH) + Batch_CyclesL.
401906 AVG_Press Average of last 5 pressure readings.
401907 Rev SOFTWARE VERSION.
401908 EventFlag
401909 RunningFlag
401910 AutoSlpStat Status of the AutoSleep input. 1 = the AutoSleep input is active (low).
401911 CalcFlow Current flow rate x 100 in GPM or LPM.
401912 XducerValidFlg
401913 to
401919
401920 ToothStat Status of the Position Sensor. The motor must be rotating for the system
None Not used.
Modbus Display only.
7 = Start Event.
8 = Stop Event.
1 = The motor is rotating.
0 = The motor is stopped.
1 = Pressure transducer is valid (> 2mA).
0 = Pressure transducer has failed (< 2mA).
to determine the validity of the position sensor.
Description
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
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