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Instructions GLC 4400 Lubrication Controller 313855H EN For controlling and monitoring single-line resistive, parallel, series progressive and dual line, automatic lubrication systems. Not for use in explosive atmospheres! Part No.: 24B591, Series C: DC Power Part No.: 24B596, Series C: AC Power Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. ti14059 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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found 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 and national codes and regulations. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. • Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only. • Do not alter or modify equipment. • Use equipment only for its intended purpose. Call your distributor for information. • Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. • Do not kink or over bend hoses or use hoses to pull equipment. • Keep children and animals away from work area. • Comply with all applicable safety regulations. 2 313855H Component Identification Component Identification Keypad, Display, and Icons E ! A F D C B FIG. 1 Run Mode Functions Direction Arrows Keypad Icons A Up and Down Arrow Keys: Adjusts contrast. NOTE: Keypad Icons are described on Icon’s page 4. B Left and Right Arrow Keys: Adjusts brightness. • Press the LEFT and RIGHT ARROW keys simultaneously to manually start a pump cycle. 313855H C ENTER Key: Press and hold for 3 seconds. Allows access to setup. D RESET Key: Press and hold for 3 seconds. Resets unit to normal Pump Off state. Also is used to reset an alarm condition. E FUNTION LED: See page 4 for a description of these icons. F DISPLAY 3 Component Identification Icons The following icons are used throughout this instruction manual and on the Controller’s Run and Setup Screens. Refer to this table if you are unsure of an Icon’s meaning. Power on indicator*. When power is supplied to the Lubrication Controller, Green LED illuminates under Function Icon located above display screen. Pump On indicator*. When Pump On is running, Yellow LED illuminates under Function Icon located above display screen. Icon also is displayed on top left side of Prelube Run screens (see page 30). Pump Off indicator. When Pump Off is running, icon is displayed on top left side of Run screens (see page 31). Alarm event activated. LED illuminates when an Alarm event occurs. Icon also displays on top right side of Alarm screen (see page 32). Brightness adjustment. Use the LEFT/RIGHT Arrow key to adjust display backlight (brighter or darker) (see page 17). Contrast adjustment. Use the UP/DOWN Arrow key to adjust screen contrast (see page 17). Low Level Alarm. Icon appears on display screen. Indicates the lubrication fluid level is low. Change Icon. When icon appears on PIN setup screen, indicates changes can be made to PIN number or new PIN number can be added. Lock Icon. Indicates the Setup screens are password protected and require the user to provide the correct PIN number to access this feature. Setup mode active. When user is on the Main Setup Screen in the Setup Mode, icon displays on the upper right corner of the display screen. Timer mode activated. Displays on right side of screen when a Timer Setup or Run screen is displayed (pages 18, 21, 30 and 31). Pressure mode activated. Icon displays on right side screen when a Pressure Setup or Run screen is displayed (page 19 and 30). Pressure mode error. Icon displays on alarm screen to signal the allotted time ran out before the pressure switch was tripped. Cycle count mode active*. Yellow LED illuminates under Function Icon located above display screen. Icon also appears on right side of display screen when a Cycle Setup or Run screen is displayed (page 19 and 31). Machine count active. Displays on right side of Setup or Run screen when a Machine Count screen is displayed (page 21 and 32). Machine count error. When icon displays on alarm screen, indicates the set number of machine counts was not received before time expired (page 32). This would trigger an alarm event. Cycle switch input error. Icon displays in center of Alarm screen to indicate the allotted time ran out before the programmed number of cycle switch activations was received (see Alarm Screen, page 32). Alarm*. Red LED illuminates under symbol located above display screen. Icon also appears on display when no valid run values have been entered. *See Field E, page 3 for location of these Function Icons. 4 313855H Installation Installation Typical Installation The installation shown in FIG. 2 is only a guide for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs. K E ! H Controller Capabilities Low Reservoir Level switch (user provided) J Pressure or Cycle Switch for system control (user provided B2 B3 B1 Machine Counts for System Control (user provided) C A Pressure Switch or Cycle Switch Alarm D Low Level Alarm G F Remote Alarm Device (Light or Horn) (user provided) FIG. 2 A B Main Air Supply Filter/Regulator/Lubricator Assembly B1 - Filter B2 - Regulator B3 - Lubricator C D E F G H J K Injector Banks Lubrication Controller Model 24B591 12/24VDC Power Supply Model 24B596 115/230VAC Power Supply Air Solenoid Valve Pump Module Ignition Switch High-Pressure Lubricant Supply Lines 313855H 5 Installation Installing the Lubrication Controller #6 screws (not provided) to secure junction box to mounting surface. AUTOMATIC SYSTEM ACTIVATION HAZARD Unexpected activation of the system could result in serious injury, including skin injection and amputation. a a This device has an automatic timer that activates the pump lubrication system when power is connected or when exiting the programming function. Before you install or remove the Lubrication Controller from the system, disconnect and isolate all power supplies and relieve all pressure. 1. Select a flat surface to install the Lubrication Controller. Drill mounting holes. Refer to Mounting Hole Layout provided in the Technical Data section of this manual, page 34. NOTICE Pre-drill and use designated mounting holes in Lubrication Controller box only. Failure to use designated mounting holes can cause circuit board damage. 2. Remove Lubrication Controller cover and align junction box with predrilled holes (FIG. 3, (a). Use four, a a * FIG. 3 * Parts not supplied. To maintain IP69K rating, proper connectors must be used. Grounding 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. jumper motor ground sensor ground b 1. Loosen M6 screws from (b). 2. Attach up to 3 ground wires to (b) using appropriate sized M6 ring terminal (not provided). ground 3. If more than 3 wires are used, attach necessary amount of jumpers to other adjacent screw terminals. FIG. 4 6 313855H Installation System Configuration and Wiring The System Configuration Diagrams (FIG. 5 - FIG. 7), Sensor Wiring Diagrams (FIG. 8 - FIG. 10) and Wiring Diagrams (FIG. 11 - FIG. 16) on the following pages, show typical Injector, Divider Valve and Dual Line lubrication system configurations. Refer to Table 1, 2 and 3 to determine the Required System Configuration, Sensor Configuration and Wiring Diagram to use to setup your system. Table 4 shows additional (optional) setup configurations (FIG. 17 - FIG. 19). Table 1: System Configurations System Figure Page Divider Valve 5 8 Dual Line 6 Injector 7 Table 3: Modes of Operation Mode Power Figure Page Time ON/Time OFF DC 11 12 9 Time ON/Time OFF AC 12 12 10 Cycle ON or Pressure ON/Time OFF DC 13 13 Cycle ON or Pressure ON/Time OFF AC 14 13 Cycle ON or Pressure ON/Machine Count OFF DC 15 14 Cycle ON or Pressure ON/Machine Count OFF AC 16 14 Table 2: Sensor Wiring Configurations Sensor Figure Page Dry Contact 8 11 Sourcing 9 11 Sinking 10 11 Table 4: Optional I/O Wiring Diagrams System Mode Power Supply Wiring Diagram Low Level Switch FIG. 17, page 15 External Manual Run FIG. 17, page 15 O.K. Contact Out FIG. 17, page 15 Auxiliary and Low Level Alarm Out 313855H DC: FIG. 18, page 16 115/230 VAC: FIG. 19, page 16 7 Installation System Configuration Divider Valve System Master Divider Valve Cycle Switch Pump Reservoir Secondary Divider Valves Low Level Switch Machine Count Switch Remote Manual Run GLC 4400 Pump On/Off External O.K. External Low Level Alarm External Alarm Cycle Machine Count FIG. 5 8 313855H Installation Dual Line System Lubrication Points Cycle Switch Reverser Bi-flo Valves Vent Line Machine Count Swtich Pump Reservoir Low Level Switch GLC 4400 Remote Manual Run External O.K. Pump On/Off External Low Level Alarm External Alarm Cycle Machine Count FIG. 6 313855H 9 Installation Injector System Lubrication Points Injectors Pressure Switch Vent Line Machine Count Switch Pump Reservoir Low Level Switch Pump On/Off Remote Manual Run External O.K. GLC 4400 External Low Level Alarm External Alarm Cycle Machine Count FIG. 7 10 313855H Installation System Wiring NOTICE Do not connect any of the SW+ (13,9,5,1) and SW(16,12,8,4) pins together, either directly or via a switch closure. Doing so will create a short circuit condition which will disable and potentially damage the controller. NOTE: On an AC controller (p/n 24B596), the J7 strip is line (input) voltage but the J6 strip is all 24VDC. On a DC controller (p/n 24B59‘), the J6 and J7 terminals all carry the input voltage. Input Sensor Wiring: DRY CONTACT SWITCH SINK SWITCH - 2 or 3 Wire Type J6 J6 4 (SW -) 4 (SW -) 3 (SEN (x)) 3 (SEN (x)) 2 (IN (x)) 2 (IN (x)) 1 (SW +) 1 (SW +) x = sensor input 1,2,3 or 4 FIG. 8 x = sensor input 1,2,3 or 4 FIG. 10 SOURCE SWITCH - 2 or 3 Wire Type J6 4 (SW -) 3 (SEN (x)) 2 (IN (x)) 1 (SW +) x = sensor input 1,2,3 or 4 FIG. 9 313855H 11 Installation Pump ON = Time; Pump OFF = Time 9 - 30VDC J6 16 (SW-) 1(IN) 15 (SEN4) 2(COM) 14 (IN4) 13 (SW+) 9 - 30 VDC Battery 3(OUT1) 12 (SW-) 4(COM) + 11 (SEN3) Air Solenoid 10 (IN3) OUTPUTS 5(OUT2) 9 (SW+) 6(COM) 8 (SW-) (Voltage = Battery Voltage) Pump Solenoid 7(OUT3) Count -PWR+ + Manual Ignition Switch 7 (SEN2) 6 (IN2) 8(COM) Low Level J7 4 (SW-) 5A max. 3 (SEN1) 10(OUT4) 11 2 (IN1) NC 1 (SW+) Press/ Cycle 5 (SW+) 9(OUT4) FIG. 11 *Dry Contact, FIG. 8 shown. For other configuration, see FIG. 9 or FIG. 10. 100VAC/240VAC Ignition Switch J6 15 (SEN4) 14 (IN4) 100-240 VAC 3(OUT1) 13 (SW+) 12 (SW-) 4(COM) Air Solenoid OUTPUTS 9 (SW+) 6(COM) 7(OUT3) 11 (SEN3) 10 (IN3) 5(OUT2) (Voltage = Line Voltage) Pump Solenoid 8 (SW-) 7 (SEN2) 6 (IN2) 8(COM) Manual 2(COM) Count 16 (SW-) 1(IN) Low Level -PWR+ J7 10(OUT4) 11 NC 10A max. 4 (SW-) 3 (SEN1) 2 (IN1) 1 (SW+) Press/ Cycle 5 (SW+) 9(OUT4) FIG. 12 12 313855H Installation System Wiring Pump ON = Cycle or Pressure; Pump OFF = Time 9 - 30VDC J6 Ignition Switch 15 (SEN4) 2(COM) 14 (IN4) 13 (SW+) 9 - 30 VDC Battery 3(OUT1) 12 (SW-) 4(COM) + OUTPUTS 5(OUT2) Air or Hydraulic Solenoid Pump Power or Motor 11 (SEN3) 10 (IN3) Electric Vent Valve 9 (SW+) 6(COM) 8 (SW-) (Voltage = Battery Voltage) Pump Solenoid 7(OUT3) Count 16 (SW-) 1(IN) Manual -PWR+ + 7 (SEN2) 6 (IN2) 8(COM) Low Level J7 4 (SW-) 5A max. 3 (SEN1) 10(OUT4) 11 2 (IN1) * Dry Contact Switch NC 1 (SW+) Press/ Cycle 5 (SW+) 9(OUT4) FIG. 13 *Dry Contact, FIG. 8 shown. For other configuration, see FIG. 9 or FIG. 10. 100VAC/240VAC J6 Ignition Switch 15 (SEN4) 2(COM) 14 (IN4) 12 (SW-) 4(COM) OUTPUTS 5(OUT2) Air or Hydraulic Solenoid Pump Power or Motor 11 (SEN3) 10 (IN3) Electric Vent Valve 9 (SW+) 6(COM) 7(OUT3) Manual 13 (SW+) 100-240 VAC 3(OUT1) Count 16 (SW-) 1(IN) 8 (SW-) (Voltage = Line Voltage) Pump Solenoid 7 (SEN2) 6 (IN2) 8(COM) Low Level -PWR+ J7 4 (SW-) 10A max. 3 (SEN1) 10(OUT4) 11 NC * Dry Contact Switch 2 (IN1) 1 (SW+) Press/ Cycle 5 (SW+) 9(OUT4) FIG. 14 *Dry Contact, FIG. 8 shown. For other configuration, see FIG. 9 or FIG. 10. 313855H 13 Installation System Wiring Pump ON = Cycle or Pressure; Pump OFF = Machine Count 9 - 30VDC J6 Ignition Switch + 16 (SW-) 15 (SEN4) 2(COM) 3(OUT1) 4(COM) + OUTPUTS 5(OUT2) Air or Hydraulic Solenoid Pump Power or Motor 14 (IN4) * Dry Contact Switch 13 (SW+) 12 (SW-) 11 (SEN3) 10 (IN3) Electric Vent Valve 9 (SW+) 6(COM) 8 (SW-) (Voltage = Battery Voltage) Pump Solenoid 7(OUT3) Manual 9 - 30 VDC Battery Low Level -PWR+ 1(IN) Count J7 7 (SEN2) 6 (IN2) 8(COM) 5 (SW+) 4 (SW-) 5A max. 3 (SEN1) 10(OUT4) 11 Press/ Cycle 9(OUT4) 2 (IN1) * Dry Contact Switch NC 1 (SW+) FIG. 15 Dry Contact, FIG. 8 shown. For other configuration, see FIG. 9 or FIG. 10. 100VAC/240VAC J6 Ignition Switch 15 (SEN4) * Dry Contact Switch 100-240 VAC 3(OUT1) 4(COM) OUTPUTS 5(OUT2) Air or Hydraulic Solenoid Pump Power or Motor 13 (SW+) 12 (SW-) 11 (SEN3) 10 (IN3) Electric Vent Valve 9 (SW+) 6(COM) 7(OUT3) 14 (IN4) Manual 2(COM) Count 16 (SW-) 1(IN) 8 (SW-) (Voltage = Line Voltage) Pump Solenoid 7 (SEN2) 6 (IN2) 8(COM) Low Level -PWR+ J7 4 (SW-) 10A max. 3 (SEN1) 10(OUT4) 11 NC * Dry Contact Switch 2 (IN1) 1 (SW+) Press/ Cycle 5 (SW+) 9(OUT4) FIG. 16 Dry Contact, FIG. 8 shown. For other configuration, see FIG. 9 or FIG. 10. 14 313855H Installation System Wiring Options NOTICE Do not connect any of the SW+ (13,9,5,1) and SW(16,12,8,4) pins together, either directly or via a switch closure. Doing so will create a short circuit condition which will disable and potentially damage the controller. All Units: Low Level Switch / External Manual Run / O.K. Contact Out J6 15 (SEN4) 2(COM) 14 (IN4) 12 (SW-) 11 (SEN3) OUTPUTS 5(OUT2) * Dry Contact Switch 6(COM) 7(OUT3) 11 9 (SW+) 8 (SW-) 7 (SEN2) 8(COM) 10(OUT4) 10 (IN3) O.K. Contact * Dry Contact Switch (Closed = O.K.) NC 6 (IN2) Low Level 4(COM) Manual 13 (SW+) 3(OUT1) 9(OUT4) Count 16 (SW-) 1(IN) 5 (SW+) 4 (SW-) 3 (SEN1) 2 (IN1) 1 (SW+) Press/ Cycle -PWR+ J7 FIG. 17 Dry Contact, FIG. 8 shown. For other configuration, see FIG. 9 or FIG. 10. 313855H 15 Installation System Wiring Options: Alarm Out 9 - 30VDC J6 15 (SEN4) 2(COM) 14 (IN4) 12 (SW-) 4(COM) 11 (SEN3) 5(OUT2) 10 (IN3) Low Level 6(COM) 9 (SW+) Manual 13 (SW+) 3(OUT1) OUTPUTS Count 16 (SW-) 1(IN) 8 (SW-) 7(OUT3) 1 A Fuse Alarm 8(COM) 7 (SEN2) + Alarm +9-30V 1 Amp Max 6 (IN2) Low Level -PWR+ J7 4 (SW-) 1 A Fuse 10(OUT4) NC 11 + Alarm +9-30V 1 Amp Max 3 (SEN1) 2 (IN1) 1 (SW+) Press/ Cycle 5 (SW+) 9(OUT4) Aux (cycle, pressure, machine count) FIG. 18 100/240VAC J6 15 (SEN4) 2(COM) 14 (IN4) 12 (SW-) 4(COM) OUTPUTS 6(COM) 11 (SEN3) 10 (IN3) Low Level 9 (SW+) 8 (SW-) 7(OUT3) 8(COM) Manual 13 (SW+) 3(OUT1) 5(OUT2) Count 16 (SW-) 1 A Fuse Alarm Alarm 100-240 VAC 1 Amp Max 7 (SEN2) 6 (IN2) Low Level -PWR+ J7 1(IN) 10(OUT4) 11 NC 4 (SW-) 1 A Fuse Alarm 100-240 VAC 1 Amp Max 3 (SEN1) 2 (IN1) 1 (SW+) Press/ Cycle 5 (SW+) 9(OUT4) Aux (cycle, pressure, machine count) FIG. 19 16 313855H Setup Setup System Setup - PIN Mode Enabled 1. To access Setup Mode, hold down the ENTER key for 3 seconds. The PIN ModeScreen shown in FIG. 21 displays. See Electric Connection Warning, page 7. When you first turn on power to the Lubrication Controller, the following identification screen displays. A C NOTE: • The Pin Mode screen shown in FIG. 21 only displays when the PIN mode is enabled. For setting up systems when the PIN mode is not enabled, go to System Setup instructions on page 18. • Before the PIN Mode screen shown in FIG. 21 can display, the PIN Mode must be enabled in an previous setup sequence. See PIN Setup, page 25. D B FIG. 20 A Display Contrast Adjustment: UP and DOWN Arrows can be used to adjust the display contrast. B Brightness Adjustment: LEFT and RIGHT Arrows can be used to adjust the backlight brightness. NOTE: Contrast and Brightness adjustments can be made on any Run Screen at any time. C Software (Part Number): 15Y354 D (Software) Version: 1.01.XX NOTE: The example of the Software Version (D) shown in FIG. 20 displays “XX” as the last two numerals. On your Controller’s screen, the “XX” will be replaced by the current software version numbers. FIG. 21 2. The PIN Mode screen in FIG. 21 displays. NOTE: The PIN Code prompt spaces are initially blank. 3. Use the LEFT / RIGHT arrow to position the cursor over the first blank PIN Code prompt field (FIG. 21). 4. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the PIN code is displayed in the field. 5. Use the RIGHT arrow to move the cursor to the next field. 6. Repeat steps 4 and 5 for each PIN Code prompt field. 7. When finished, press ENTER. 313855H 17 Setup 8. If the PIN Code you entered is correct, the System Setup Screen, shown in FIG. 22 displays. 9. If the PIN Code you entered is incorrect, the digits flash. The Code must be re-entered by repeating steps 4 and 5. NOTE: • As soon as any arrow key is pressed, the numerals stop flashing. • To leave any Setup Screen and return to normal operation, press RESET. FIG. 23 System Setup 1. Use the UP/DOWN Arrow keys to move the cursor over PUMP ON. Main Screen 2. Press ENTER to display the PUMP ON setup screen. TIMER Setup FIG. 22 1. Use the UP/DOWN arrows to move the cursor up and down through the list of setup screens (FIG. 22). FIG. 24 2. Press ENTER to display the selected setup screen. 3. When all setup operations are complete, press RESET to return to normal operation. PUMP ON Setup Pump On is the length of time the pump runs before its cycle is terminated by either a timer, a specific number of cycles or a certain pressure threshold is attained. NOTE: Time is displayed in HH:MM:SS. 1. Use the Arrow keys to move the cursor over the PUMP ON time box. 2. Press ENTER. 3. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the PUMP ON time is displayed in the field. 4. Use the RIGHT arrow to move the cursor to the next field. 5. Repeat steps 3 and 4 until the desired time is displayed. 6. Use the Arrow keys to move the cursor over the ENDED BY pull-down list. 18 313855H Setup 7. Press ENTER. CYCLE END Setup 8. Select TIMER from the pull-down list. 9. Press RESET. The Main Screen displays. NOTE: When TIMER is selected, the Timer Icon will display on the top right corner of the screen. PRESSURE Setup FIG. 26 NOTE: Time is displayed in HH:MM:SS. 1. Use the Arrow keys to move the cursor over the PUMP ON time box. 2. Press ENTER. NOTE: Time is displayed in HH:MM:SS. 3. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the PUMP ON time is displayed in the field. 1. Use the Arrow keys to move the cursor over the PUMP ON time box. 4. Use the RIGHT arrow to move the cursor to the next field. 2. Press ENTER. 5. Repeat steps 3 and 4 until the desired time is displayed. 3. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the PUMP ON time is displayed in the field. 6. Use the Arrow keys to move the cursor over the ENDED BY pull-down list. FIG. 25 4. Use the RIGHT arrow to move the cursor to the next field. 5. Repeat steps 3 and 4 until the desired time is displayed. 7. Press ENTER. 8. Select CYCLE from the pull-down list. 9. Press ENTER. 6. Use the Arrow keys to move the cursor over the ENDED BY pull-down list. 7. Press ENTER. 8. Select PRESSURE from the pull-down list. 9. Press RESET. The Main Screen, page 18 displays. NOTE: When PRESSURE is selected, the Pressure Icon will display on the top right corner of the screen. 313855H 19 Setup Cycle Mode Selection PUMP OFF Setup If the Cycle Mode is selected you will also be prompted to set the desired number of cycles. Sets up how the PUMP OFF cycle is ended: Time, Machine Count switch activation, or Machine Count activations limited by a maximum time. NOTE: A cycle is equal to two switch closure transitions at the cycle switch input. FIG. 28 FIG. 27 1. Use the UP/DOWN Arrow keys to move the cursor over PUMP OFF. 10. Use the Arrow keys to move the cursor over the CYCLES field. 2. Press ENTER to display the PUMP OFF setup screen. 11. Press ENTER. To Set the Pump OFF Option 12. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number you want in the CYCLES field is displayed. 13. Use the RIGHT arrow to move the cursor to the next field. Repeat step 12. NOTE: The maximum number of Cycles you can setup in this field is 99. 14. Press RESET. The Main Screen, page 18 displays. NOTE: When Cycles is selected, the Cycles Icon displays is the upper right corner of the screen. FIG. 29 1. Use the Arrow keys to move the cursor over the PUMP OFF pull-down menu. 2. Press ENTER. 3. Use the UP/DOWN Arrow keys to move cursor to select TIME, COUNT or BOTH. 4. After you make your selection, Press ENTER. 20 313855H Setup If TIME is selected: If TIME is selected you will also be prompted to set the specific amount of time. 1. Use the Arrow keys to move the cursor over the COUNTS field. 2. Press ENTER. 3. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number you want in the COUNTS field is displayed. 4. Use the RIGHT arrow to move the cursor to the next field. Repeat step 3. NOTE: The maximum number of Counts you can setup in this field is 9999. 5. Press RESET. The Main Screen, page 18 displays. FIG. 30 If BOTH is selected: 1. Use the Arrow keys to move the cursor over the TIME field. If PUMP OFF is set to BOTH, the GLC 4400 will stay in the PUMP OFF state until the entered number of machine counts is received or the time expires. 2. Press ENTER. NOTE: Time is displayed in HH:MM:SS. If TIMEOUT is set to FAULT, an alarm will occur when the time expires. 3. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the pump off TIME is displayed in the field. If TIMEOUT is set to RUN, the unit will enter PUMP ON when time expires. 4. Use the RIGHT arrow to move the cursor to the next field. If BOTH is selected you will be prompted to set the specific amount of time and determine what occurs when time expires. 5. Repeat steps 3 and 4 until the desired time is displayed. 6. Press RESET. The Main Screen, page 18 displays. If COUNT is selected: If COUNT is selected you will also be prompted to set the specific number of counts. FIG. 32 1. Use the Arrow keys to move the cursor over the COUNTS field. 2. Press ENTER. FIG. 31 313855H 3. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number you want in the COUNTS field is displayed. 21 Setup 4. Use the RIGHT arrow to move the cursor to the next field. Repeat step 3. POWER UP Setup NOTE: The maximum number of Counts you can setup in this field is 9999. 5. Use the Arrow keys to move the cursor over the TIME field. 6. Press ENTER. NOTE: Time is displayed in HH:MM:SS. 7. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the PUMP OFF time is displayed in the field. 8. Use the RIGHT arrow to move the cursor to the next field. Repeat step 7. 9. Repeat steps 7 and 8 until the desired time is displayed. 10. Press ENTER. 11. Use the Arrow keys to move the cursor over the TIMEOUT pull-down menu. FIG. 34 1. Use the UP/DOWN Arrow keys to move the cursor over POWER UP. 2. Press ENTER to display the POWER UP setup screen. Power Up can be programmed one of four ways: First: At Power Up, the normal lube cycle that was in process when power was removed, is resumed. FIG. 35 FIG. 33 12. Press ENTER. 13. When time expires: • Select FAULT if an alarm should occur. • Select RUN if unit should enter PUMP ON. 1. Use the Arrow keys to move the cursor over the POWER UP pull-down menu. 2. From the pull-down menu, select OFF. 3. Press ENTER. 4. Use the Arrow keys to move the cursor over the DELAY pull-down menu. 14. Press ENTER. 5. From the pull-down menu, select OFF. 15. Press RESET. The Main Screen, page 18 displays. 6. Press RESET. The Main Screen, page 18 displays. NOTE: If Count or Both is selected, the Count Icon displays in the upper right corner of the screen. 22 313855H Setup Second: At Power Up, a delay occurs, the pump is off; then the normal lube cycle that was in process when power was removed, is resumed. Third: At Power Up, immediately go to PUMP ON (normal on time).. FIG. 37 FIG. 36 1. Use the Arrow keys to move the cursor over the POWER UP pull-down menu. 1. Use the Arrow keys to move the cursor over the POWER UP pull-down menu. 2. From the pull-down menu, select ON. 2. From the pull-down menu, select OFF. 3. Press ENTER. 3. Press ENTER. 4. Use the Arrow keys to move the cursor over the DELAY pull-down menu. 4. Use the Arrow keys to move the cursor over the DELAY pull-down menu. 5. From the pull-down menu, select OFF. 5. From the pull-down menu, select ON. 6. Press RESET. The Main Screen, page 18 displays. 6. Press ENTER. 7. Use the Arrow keys to move the cursor over the DELAY TIME field. Fourth: At Power Up, go to programmed PUMP OFF delay time; then to normal PUMP ON. 8. Press ENTER. NOTE: Time is displayed in MM:SS. 9. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the DELAY TIME is displayed in the field. 10. Use the RIGHT arrow to move the cursor to the next field. Repeat step 9. 11. Repeat steps 9 and 10 until the desired time is displayed. FIG. 38 12. Press RESET. The Main Screen, page 18 displays. 1. Use the Arrow keys to move the cursor over the POWER UP pull-down menu. 2. From the pull-down menu, select ON. 3. Press ENTER. 4. Use the Arrow keys to move the cursor over the DELAY pull-down menu. 313855H 23 Setup 5. From the pull-down menu, select ON. Pulsed Pump Screen 6. Press ENTER. 1. Use the Arrow keys to move the cursor over the PULSE pull-down menu. 7. Use the Arrow keys to move the cursor over the DELAY TIME field. 2. Press ENTER. 8. Press ENTER. 3. Use the UP/DOWN Arrow keys to move cursor to select ON. NOTE: Time is displayed in MM:SS. 4. Press ENTER. 9. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the DELAY TIME is displayed in the field. 10. Use the RIGHT arrow to move the cursor to the next field. Repeat step 9. 11. Repeat steps 9 and 10 until the desired time is displayed. 12. Press RESET. The Main Screen, page 18 displays. PULSED Setup FIG. 41 5. Use the Arrow keys to move the cursor over the TIME OFF field. 6. Press ENTER. NOTE: The time is displayed in Seconds. 7. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number of the TIME OFF you are creating is displayed in the field. FIG. 39 1. Use the UP/DOWN Arrow keys to move the cursor over PULSED. 8. Use the RIGHT arrow to move the cursor to the next field. Repeat step 7. 9. Press ENTER. 2. Press ENTER to display the PULSED setup screen. FIG. 40 24 FIG. 42 313855H Setup 10. Use the Arrow keys to move the cursor over the TIME ON field. To enable PIN Code Entry: 11. Press ENTER. NOTE: The time is displayed in Seconds. 12. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number of the TIME ON you are creating is displayed in the field. 13. Use the RIGHT arrow to move the cursor to the next field. Repeat step 7. 14. Press ENTER. 15. Press RESET. The Main Screen, page 18 displays. FIG. 44 1. Use the Arrow keys to move the cursor over the PIN pull-down menu. NOTE: 2. Press ENTER. • The maximum Time Off and Time On is 99 seconds. • The minimum Time Off is 3 seconds. • The minimum Time On is 0 (zero) seconds. 3. Use the UP/DOWN Arrow keys to move cursor to select ON. 4. Press ENTER. PIN Setup If protection for the setup mode is desired, a PIN Code entry can be enabled. FIG. 45 5. Use the Arrow keys to move the cursor over the PIN CODE prompt field. FIG. 43 6. Use the LEFT/RIGHT arrow to position the cursor over the first blank Pin Code prompt field (FIG. 21). 1. Use the UP/DOWN Arrow keys to move the cursor over PIN CODE. 7. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the PIN code you are creating is displayed in the field. 2. Press ENTER to display the PIN CODE setup screen. 8. Use the RIGHT arrow to move the cursor to the next field. Repeat step 7 9. Repeat steps 7 and 8 for each PIN Code prompt. 10. Press RESET. The Main Screen, page 18 displays. 313855H 25 Setup DISPLAY Setup 4. Use the Arrow keys to move the cursor over the TIME ON field. FIG. 46 FIG. 48 1. Use the UP/DOWN Arrow keys to move the cursor over DISPLAY. 2. Press ENTER to display the DISPLAY setup screen. Display Backlight The display backlight can be set to turn off after a programmed amount of time. If the backlight is OFF it will turn back on when any front panel key is pressed. NOTE: Time is displayed in HH:MM. 5. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the TIME ON is displayed in the field. 6. Use the RIGHT arrow to move the cursor to the next field. Repeat step 5. 7. Repeat steps 5 and 6 until the desired time displays. 8. Press RESET. The Main Screen, page 18 displays. QUICK CYCLE Setup FIG. 47 1. Use the Arrow keys to move the cursor over the TIMER pull-down menu. 2. From the pull-down menu, select ON. 3. Press ENTER. FIG. 49 1. Use the UP/DOWN Arrow keys to move the cursor over QUICK CYCLE. 2. Press ENTER to display the QUICK CYCLE setup screen. 26 313855H Setup Quick Cycle Screen Setup 12. Repeat steps 7 - 9 for the TIME OFF field. The Quick Cycle screen setup is used to setup a Troubleshooting profile. 13. Use the Arrow keys to move the cursor over the pull-down menu. 14. Select ON. 15. The Quick Cycle begins. NOTE: • The maximum Time Off and Time On is 99 seconds. • When complete, the system returns to the Run Mode. It does not come back to the Quick Cycle Setup Screen. FIG. 50 LOW LEVEL FILTERING Setup 1. Use the Arrow keys to move the cursor over the CYCLES field. 2. Press ENTER. 3. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number you want in the CYCLES field is displayed. 4. Use the RIGHT arrow to move the cursor to the next field. Repeat step 3. NOTE: The maximum number of Cycles you can setup in this field is 99. FIG. 51 5. Use the Arrow keys to move the cursor over the TIME ON field. 1. Use the UP/DOWN Arrow keys to move the cursor over LL FILTERING. 6. Press ENTER. 2. Press ENTER to display the LL FILTERING setup screen. NOTE: Time On and Time Off in QUICK CYCLE mode only, are displayed in Seconds. 7. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number you want to use in the TIME ON field is displayed in the field. 8. Use the RIGHT arrow to move the cursor to the next field. Repeat step 7. 9. Press ENTER. 10. Use the Arrow keys to move the cursor over the TIME ON field. 11. Press ENTER. 313855H 27 Setup Low Level Filtering Screen Setup The Low Level Filtering screen setup is used to filter out spurious signals from rotating paddle type low level sensors. NOTE: When using the GLC4400 with the G3 Automatic Lubrication Pump, it is recommended that the low level filtering be set to G3 defaults. The NUMBER field determines how many signal activations are required to set a fault. The TIME field determines the amount of RUN time required without an activation to reset the activation count to 0 (zero). 8. Use the RIGHT arrow to move the cursor to the next field. Repeat step 7. 9. Repeat steps 7 and 8 until the desired time is displayed. 10. Press ENTER. 11. If the default values for the G3 Automatic Lubrication Pump are intended to be used, use the UP/DOWN arrows to move to the G3 DEFAULT field. 12. Press ENTER. The NUMBER and TIME values will be updated to the G3 default value. 13. Press RESET. The Main Screen, shown on page 18, displays. FIG. 52 1. Use the Arrow keys to move the cursor over the NUMBER field. 2. Press ENTER. 3. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number you want in the NUMBER field is displayed. 4. Use the RIGHT arrow to move the cursor to the next field. Repeat step 3. NOTE: The maximum number of Counts you can setup in this field is 99. 5. Use the Arrow keys to move the cursor over the TIME field. 6. Press ENTER. NOTE: Time is displayed in HH:MM:SS. 7. Use the UP/DOWN arrows to move up and down through the numbers 0-9 until the first number in the TIME field is displayed. 28 313855H Run Mode Run Mode When you first turn the Lubrication Controller power on, the identification screen shown in FIG. 53 displays. A A B C C D B D FIG. 53 FIG. 54 A Display Contrast Adjustment: UP and DOWN Arrows can be used to adjust the display contrast. A Operating Mode Identification - Sets up Pump On/ Pump Off, page 22. B Backlight Brightness Adjustment: LEFT and RIGHT Arrows can be used to adjust the backlight brightness. B Time Counter - Actual elapsed time counts down while the pump runs - set up in Pump On Setup, page 18. C Progression Bar - Real-time, visual representation of the elapsed time the pump has been on. Runs in conjunction with B. D Total Pump On Time - Shows the total amount of time the pump is on. Setup on the Pump On setup screen, page 18. NOTE: Contrast and Brightness adjustments can be made on any Run Screen at any time. C Software (Part Number): 15Y354 D (Software) Version: 1.01.XX Screen Identification The following screen is only shown as an example of the information that is displayed on a Run screen. A complete description of the icons and symbols shown in FIG. 54 is provided on page 3. 313855H 29 Run Mode Prelube Power Up • The Timer icon (D) displays and indicates the Timer Mode. Pump On Ended with Pressure A B D C FIG. 55 If Prelube is enabled (page 22), the programmed prelube sequence occurs. If no Prelube sequence has been selected, the lube cycle that was in progress at power down is resumed. FIG. 57 If the Pump On sequence has been programmed to end by a pressure switch: Pump On Ended with Time A D C • The GLC 4400 pump output relay activates (J7-3) and will stay on until a switch closure is received (J6-3) (see Setup Menus, Pump On, page 19). • The Pump On LED (A) remains on during this time. • The Pump On (C) icon displays. • The Cycle LED (B) illuminates and Pressure Mode icon (D) displays to indicate the pressure switch. • If the pressure switch closure is not received before time expires, an alarm occurs. NOTE: If Pump On is ended by a pressure switch and no Power Up delay is selected, when power to the GLC 4400 is turned on, the GLC 4400 starts at the beginning of the Pump On time instead of resuming the Pump On time where it left off. FIG. 56 If the Pump On sequence has been programmed to be ended by TIME: • The GLC 4400 pump output relay activates (J7-3) and will stay on until the time expires. (see Setup Menus, Pump On, page 18). • The Pump On LED (A) remains on during this time. • The Pump On (C) icon displays. 30 313855H Run Mode Pump On Ended with Cycle Switch Activation Pump Off Ended with Time D A A B C C D E FIG. 59 FIG. 58 If the Pump On sequence has been programmed to end by a Cycle Switch Activation: • The GLC 4400 pump output relay activates (J7-3) and will stay on until the correct number of cycle switch closures is received (J6-3) (see Setup Menus, Cycle End Setup page 19). • The Pump On LED (A) remains on during this time. • The Pump On (C) icon displays. • The Cycle LED (B) and Cycle Count Mode icon (D) display indicating the cycle switch is activated. • The cycle indicator bar (E) displays a visual representation of the cycle switch closures received. • If the set number of cycle switch closures is not received before time expires, an alarm occurs. If the Pump Off sequence has been programmed to be ended by TIME: • The GLC 4400 pump output relay activates (J7-3) and will stay off until the time expires. (see Setup Menus, Pump Off, page 20). • The Pump On LED (A) remains off during this time. • The Pump Off icon (C) displays. • The Timer Mode icon (D) displays and indicates the Timer Mode. Pump Off Ended with Machine Counts B A C D FIG. 60 If the Pump Off sequence has been programmed to be ended by MACHINE COUNTS: 313855H 31 Run Mode • The GLC 4400 pump output relay activates (J7-3) and will stay off until the correct number of counts (J6-15) occur (see Setup Menus, Pump Off, page 20). • The Pump On LED (A) remains off during this time. • The Pump Off icon (C) displays. • The Cycle LED (B) and Machine Count icon (D) display and indicate the Machine Count Switch activation. Alarms Screen When a cycle alarm event occurs the Alarm Screen, shown in FIG. 62 displays. Pump Off Ended with Machine Counts; Max Time Entered A FIG. 62 B C D To clear an alarm, hold down the Clear Key on the display Keypad (see page 3). E The following is a list of other alarm events that may display. FIG. 61 If the Pump Off sequence has been programmed to be ended by MACHINE COUNTS with a maximum time: • The GLC 4400 pump output relay activates (J7-3) and will stay off until the correct number of counts (J6-15) occur (see Setup Menus, Pump Off, page 20). • The Pump On LED (A) remains off during this time. • The Pump Off icon (C) displays. • The Cycle LED (B) and Machine Count icon (D) display and indicate the Machine Count Switch activation. • The counts indicator bar (E) displays a visual representation of the machine counts received. • If the set number of machine counts is not received before time expires, an alarm occurs. 32 Low Level Alarm. Icon appears on display screen. Indicates the lubrication fluid level is low. Pressure mode error. Icon displays on alarm screen to signal the allotted time ran out before the pressure switch was tripped. Machine count error. When icon displays on alarm screen, indicates the set number of machine counts was not received before time expired. This would trigger an alarm event. Cycle switch input error. Icon displays in center of Alarm screen to indicate the allotted time ran out before the programmed number of cycle switch activations was received. 313855H Troubleshooting Troubleshooting Description Problem No power supplied to solenoid Power light off: Timer is not receiving power. Verify connections and verify power supply. Power light on: Verify solenoid connections Timer fails to activate solenoid Solenoid faulty Pressure switch fails to shut down system Solution Replace solenoid Timer faulty Replace timer Low level or other alarm Refill reservoir Pressure switch incorrectly wired Verify proper connections Pressure switch faulty Replace pressure switch Timer faulty Replace timer Program Settings Description Modes of Operation Maximum / Minimum and Additional Comments TIMER Setup, page 18 HH:MM:SS (00:00:01 - 99:59:59) PRESSURE Setup, page 19 HH:MM:SS (00:00:01 - 99:59:59) CYCLE END Setup, page 19 HH:MM:SS (00:00:01 - 99:59:59) CYCLE MODE Selection, page 20 Cycles = 01 - 99 Time, Pressure or Cycles PUMP ON Setup, page 18 Pump ON Time: HH:MM:SS (00:00:01 - 99:59:59) Cycles: 01 - 99 (only used when mode of operation = cycles) Time, Count or Both PUMP OFF Setup, page 20 Pump OFF Time: HH:MM:SS. (00:00:01 - 99:59:59) Count: 01 - 9999 POWER UP Setup, page 22 PULSED Output (pump), page 24 MM:SS (00:01 - 59:59) Maximum Time OFF and Time ON: SS (01-99) ON / OFF PIN Number Setup, page 25 0000 - 9999 Cycles = 01 - 99 QUICK CYCLE SCREEN Setup, page 26 Time ON and Time OFF: SS (01-99) Execute: YES / NO YES / NO PRELUBE on Power Up, page 30 Delay: YES / NO TIME: MM:SS (00:01 - 59:59) 313855H 33 Technical Data Technical Data Input Contact Power Source DC - model 24B591 9 - 30 VDC Power Source AC - model 24B596 100 VAC to 240 VAC - 50/60 Hz Power consumption 24 Watts Cycle Pressure Control Input (optional) Normally open pressure or cycle switch Machine Count Control Input (optional) Machine count control switch Lubrication level (optional) Normally open level switch, closes upon low level Remote Manual Run Input Normally open remote manual run switch Outputs Pump control Voltage Pump Control Voltage = Power Source Power Source Max Switching Voltage 250 VAC, 100 VDC Max Switching Current 10 A (AC), 5A (DC) Minimum Switching Capacity 100 mA @ 5 VDC Low Level Alarm, normally open (optional) Voltage Power Source Max Switching Voltage 250 VAC, 30 VDC Max Switching Current 5A (AC), 5A (DC) Minimum Switching Capacity 100 mA @ 5 VDC Auxiliary Alarm, normally open (optional) Voltage Power Source Max Switching Voltage 250 VAC, 30 VDC Max Switching Current 5A (AC), 5A (DC) Minimum Switching Capacity 100 mA @5 VDC Status OK, normally open (optional) Voltage Voltage-free Contact Power Source Max Switching Voltage 250 VAC, 100 VDC Max Switching Current 10 A (AC), 5A (DC) Minimum Switching Capacity Protection grade 100 mA @ 5 VDC Enclosure Material Membrane Material Bushing IP69K Fiberglass reinforced polyester Polyester Ethylene Propylene Diene Monemer Rubber (EDPM) Operating temperature range - 40°F to 145°F (- 40°C to 63°C) Storage Temperature - 13°F to 145°F (- 25°C to 63°C) 34 313855H Dimensions Dimensions Mounting Hole Layout 4.8 in. (122 mm) 3.23 in. (82.0 mm) 4.72 in. (120 mm) 3.58 in. (90.85 mm) 313855H 4.17 in. (105.92 mm) 35 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 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 manufacturer. 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 rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For the latest information about Graco products, visit www.graco.com. TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590 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 changes at any time without notice. For patent information, see www.graco.com/patents. Original instructions. This manual contains English. MM 313855 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2009, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revised December 2013
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