Graco GLC 4400 Instructions Manual Download

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Instructions

GLC 4400
Lubrication Controller

313855K

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 E: DC Power
Part No.: 24B596, Series E: AC Power

Important Safety Instructions

Read all warnings and instructions in this
manual. Save these instructions.

ti14059

Summary of Contents for GLC 4400

Page 1: ...esistive parallel series progressive and dual line automatic lubrication systems Not for use in explosive atmospheres Part No 24B591 Series E DC Power Part No 24B596 Series E AC Power Important Safety Instructions Read all warnings and instructions in this manual Save these instructions ti14059 EN ...

Page 2: ... 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 ...

Page 3: ...Press the LEFT and RIGHT ARROW keys simultaneously to manually start a pump cycle Keypad Icons NOTE Keypad Icons are described on Icon s page 4 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 FIG 1...

Page 4: ...tes 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 24 27 37 and 38 Pressure mode activ...

Page 5: ...bricator C Air Solenoid Valve D Pump Module E Ignition Switch F High Pressure Lubricant Supply Lines G Injector Banks H Lubrication Controller J Model 24B591 12 24VDC Power Supply K Model 24B596 115 230VAC Power Supply FIG 2 Controller Capabilities B1 B2 B3 C E H G F D Low Reservoir Level switch user provided Pressure or Cycle Switch for system control user provided Machine Counts for System Contr...

Page 6: ...hort circuit 1 Loosen M6 screws from b 2 Attach up to 3 ground wires to b using appropriate sized M6 ring terminal not provided 3 If more than 3 wires are used attach necessary amount of jumpers to other adjacent screw termi nals AUTOMATIC SYSTEM ACTIVATION HAZARD Unexpected activation of the system could result in seri ous injury including skin injection and amputation This device has an automati...

Page 7: ...ations Table 2 Sensor Wiring Configurations Table 3 Modes of Operation Table 4 Optional I O Wiring Diagrams System Figure Page Divider Valve 5 8 Dual Line 6 9 Injector 7 10 Sensor Figure Page Dry Contact 8 11 Sourcing 9 11 Sinking 10 11 Mode Power Figure Page Time ON Time OFF DC 11 12 Time ON Time OFF AC 12 12 Cycle ON or Pressure ON Time OFF DC 13 13 Cycle ON or Pressure ON Time OFF AC 14 13 Cycl...

Page 8: ...G 5 GLC 4400 External Low Level Alarm Remote Manual Run Machine Count Switch Low Level Switch Pump Reservoir Master Divider Valve Secondary Divider Valves Cycle Switch Divider Valve System External O K Pump On Off External Alarm Cycle Machine Count ...

Page 9: ... External Alarm Cycle Machine Count External Low Level Alarm External O K Low Level Switch Pump Reservoir Dual Line System Cycle Switch Bi flo Valves Lubrication Points Vent Line Pump On Off Reverser Remote Manual Run Machine Count Swtich ...

Page 10: ...C 4400 External Low Level Alarm Remote Manual Run Machine Count Switch Low Level Switch Pump Reservoir Injector System Pressure Switch Injectors Lubrication Points Vent Line Pump On Off External O K External Alarm Cycle Machine Count ...

Page 11: ... DRY CONTACT SWITCH SOURCE SWITCH 2 or 3 Wire Type SINK SWITCH 2 or 3 Wire Type 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 FIG 8 FIG 9 x sensor input 1 2 3 or 4 1 SW 2 IN x 3 SEN x 4 SW J6 1 SW 4 SW J6 x sensor input 1 2 3 ...

Page 12: ...UT3 8 COM 9 OUT4 10 OUT4 11 OUTPUTS PWR J6 J7 Air Solenoid Voltage Battery Voltage Pump Solenoid Ignition Switch 9 30 VDC Battery Manual Low Level Press Cycle Count 5A max NC FIG 12 16 SW 15 SEN4 14 IN4 13 SW 12 SW 11 SEN3 10 IN3 9 SW 8 SW 7 SEN2 6 IN2 5 SW 4 SW 3 SEN1 2 IN1 1 SW 1 IN 2 COM 3 OUT1 4 COM 5 OUT2 6 COM 7 OUT3 8 COM 9 OUT4 10 OUT4 11 OUTPUTS PWR J6 J7 Air Solenoid Ignition Switch Manu...

Page 13: ...Ignition Switch Manual Low Level Press Cycle Count Voltage Battery Voltage Pump Solenoid 9 30 VDC Battery Dry Contact Switch 5A max NC Electric Vent Valve FIG 14 Dry Contact FIG 8 shown For other configuration see FIG 9 or FIG 10 10A max 16 SW 15 SEN4 14 IN4 13 SW 12 SW 11 SEN3 10 IN3 9 SW 8 SW 7 SEN2 6 IN2 5 SW 4 SW 3 SEN1 2 IN1 1 SW 1 IN 2 COM 3 OUT1 4 COM 5 OUT2 6 COM 7 OUT3 8 COM 9 OUT4 10 OUT...

Page 14: ...tage Battery Voltage Pump Solenoid 9 30 VDC Battery Dry Contact Switch Dry Contact Switch NC Air or Hydraulic Solenoid Pump Power or Motor Electric Vent Valve FIG 16 Dry Contact FIG 8 shown For other configuration see FIG 9 or FIG 10 10A max 16 SW 15 SEN4 14 IN4 13 SW 12 SW 11 SEN3 10 IN3 9 SW 8 SW 7 SEN2 6 IN2 5 SW 4 SW 3 SEN1 2 IN1 1 SW 1 IN 2 COM 3 OUT1 4 COM 5 OUT2 6 COM 7 OUT3 8 COM 9 OUT4 10...

Page 15: ...te a short circuit condition which will disable and potentially damage the controller FIG 17 Dry Contact FIG 8 shown For other configuration see FIG 9 or FIG 10 16 SW 15 SEN4 14 IN4 13 SW 12 SW 11 SEN3 10 IN3 9 SW 8 SW 7 SEN2 6 IN2 5 SW 4 SW 3 SEN1 2 IN1 1 SW 1 IN 2 COM 3 OUT1 4 COM 5 OUT2 6 COM 7 OUT3 8 COM 9 OUT4 10 OUT4 11 OUTPUTS PWR J6 J7 Manual Low Level Press Cycle Count O K Contact Closed ...

Page 16: ...V 1 Amp Max 1 A Fuse Low Level Alarm 9 30V 1 Amp Max 1 A Fuse Manual Low Level Press Cycle Count Aux cycle pressure machine count NC FIG 19 16 SW 15 SEN4 14 IN4 13 SW 12 SW 11 SEN3 10 IN3 9 SW 8 SW 7 SEN2 6 IN2 5 SW 4 SW 3 SEN1 2 IN1 1 SW 1 IN 2 COM 3 OUT1 4 COM 5 OUT2 6 COM 7 OUT3 8 COM 9 OUT4 10 OUT4 11 OUTPUTS PWR J6 J7 Alarm Alarm 100 240 VAC 1 Amp Max 1 A Fuse Low Level 1 A Fuse Manual Low Le...

Page 17: ... If G3 Pump select PADDLE 3 See programming instructions sections of manual for machine count programming information Signal J Signal J Pin Power J7 1 2 Pressure Switch J6 2 Pump J7 3 4 Low Level J6 6 opt LL Alarm J7 5 6 opt Remote Run J6 10 opt Aux Alarm J7 7 8 opt Machine Count3 J6 14 opt Prelube ADVANCED POWER UP Lubrication Delay at Startup ADVANCED POWER UP Reciprocate Pump ADVANCED PULSED Re...

Page 18: ...PADDLE 3 See programming instructions sections of manual for machine count programming information Signal J Signal J Pin Power J7 1 2 Pressure Switch J6 2 Pump J7 3 4 Low Level J6 6 opt LL Alarm J7 5 6 opt Remote Run J6 10 opt Aux Alarm J7 7 8 opt Machine Count3 J6 14 opt Prelube ADVANCED POWER UP Lubrication Delay at Startup ADVANCED POWER UP Reciprocate Pump ADVANCED PULSED Recommended ADVANCED ...

Page 19: ...LE 3 See programming instructions sections of manual for machine count programming information Signal J Signal J Pin Power J7 1 2 Pressure Switch J6 2 Pump J7 3 4 Low Level J6 6 opt LL Alarm J7 5 6 opt Remote Run J6 10 opt Aux Alarm J7 7 8 opt Machine Count3 J6 14 opt Prelube ADVANCED POWER UP Lubrication Delay at Startup ADVANCED POWER UP Reciprocate Pump ADVANCED PULSED Recommended ADVANCED PIN ...

Page 20: ...or 3 seconds The PIN ModeScreen shown in FIG 21 displays NOTE The Pin Mode screen shown in FIG 21 only displays when the PIN mode is enabled For setting up sys tems when the PIN mode is not enabled go to Sys tem Setup instructions on page 21 Before the PIN Mode screen shown in FIG 21 can display the PIN Mode must be enabled in an previ ous setup sequence See PIN Setup page 31 2 The PIN Mode screen...

Page 21: ...OTE As soon as any arrow key is pressed the numerals stop flashing To leave any Setup Screen and return to normal operation press RESET System Setup NOTE For Series D or earlier models proceed to Advanced System Setup page 24 Advanced System Setup is the original setup methodology Setup Instructions Series E Use the UP Down Arrow keys to select between Quick System Setup and Advanced System Setup ...

Page 22: ... Enter ON Time in HH MM SS by using the LEFT RIGHT arrows to select digit and use the UP DOWN arrows to change time b Pressure Enter ON Timeout in HH MM SS buy using the LEFT RIGHT arrows to select digit and use the UP DOWN arrows to change time If pressure is not reached within this timeout the controller will enter a fault state c Cycles Defines the number of cycles needed to finish a lubricatio...

Page 23: ...d use the UP DOWN arrows to change value Sets time between lubrica tion events ii Enter number of machine counts between lubrication cycles by using LEFT RIGHT arrows to select the digit and UP DOWN arrows to change value iii NOTE Timeout behavior is only selectable through ADVANCED SYSTEM SETUP page 24 Default behavior is to enter a fault on timeout 3 Low Level a Skip Makes no change to existing ...

Page 24: ... Press ENTER to display the PUMP ON setup screen TIMER Setup 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 unti...

Page 25: ...rom the pull down list 9 Press RESET The Main Screen page 24 displays NOTE When PRESSURE is selected the Pressure Icon will display on the top right corner of the screen CYCLE END Setup 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 ...

Page 26: ...ximum number of Cycles you can setup in this field is 99 14 Press RESET The Main Screen page 24 displays NOTE When Cycles is selected the Cycles Icon dis plays is the upper right corner of the screen PUMP OFF Setup Sets up how the PUMP OFF cycle is ended Time Machine Count switch activation or Machine Count acti vations limited by a maximum time 1 Use the UP DOWN Arrow keys to move the cursor over...

Page 27: ...p 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 24 displays If BOTH is selected If PUMP OFF is set to BOTH the GLC 4400 will stay in the PUMP OFF state until the entered ...

Page 28: ...lect FAULT if an alarm should occur Select RUN if unit should enter PUMP ON 14 Press ENTER 15 Press RESET The Main Screen page 24 displays NOTE If Count or Both is selected the Count Icon dis plays in the upper right corner of the screen POWER UP Setup Define behavior of the controller during power ON Default behavior is to continue program from point of power OFF 1 Use the UP DOWN Arrow keys to m...

Page 29: ... 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 dis played 12 Press RESET The Main Screen page 24 displays Third At Power Up immediately go to PUMP ON normal on time 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 EN...

Page 30: ...LAY 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 dis played 12 Press RESET The Main Screen page 24 displays PULSED Setup For systems requiring power to the pump to be turned on and off during a lubrication event the user can utilize the pulse mode 1 Use the UP DOWN Arrow keys to move the ...

Page 31: ...0 Use the Arrow keys to move the cursor over the TIME ON field 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 24 displ...

Page 32: ...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 for each PIN Code prompt 10 Press RESET The Main Screen page 24 displays DISPLAY Setup Adjust setting related to the display and backlight 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 b...

Page 33: ...sed to setup a Trou bleshooting profile 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 5 Use the...

Page 34: ...brication Pump it is recommended that the low level filtering be set to G3 defaults The NUMBER field determines how many signal activa tions 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 MODE Field available in Series D or later models only The MODE field determines the behavior of the control ler...

Page 35: ...ime 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 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 dis played 10 Press ENTER 11 If the default values for the G3 Automatic Lubrica tion Pump are intended to be used use the UP D...

Page 36: ...ware 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 com plete description of the icons and symbols shown in FIG 55 is provided on page 3 A Operating Mode Identification Sets up Pump On Pump Off page 28 B Time Counter Actual elapsed time counts down while the pump runs set up in Pump On Setup page 24 C Pr...

Page 37: ...p On Ended with Pressure If the Pump On sequence has been programmed to end by a pressure switch 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 25 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 ...

Page 38: ... icon D display indicating the cycle switch is activated The cycle indicator bar E displays a visual repre sentation of the cycle switch closures received If the set number of cycle switch closures is not received before time expires an alarm occurs Pump Off Ended with Time 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 ...

Page 39: ...d with Machine Counts Max Time Entered 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 26 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 dis p...

Page 40: ...cates 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 ...

Page 41: ...Operation Maximum Minimum and Additional Comments TIMER Setup page 24 HH MM SS 00 00 01 99 59 59 PRESSURE Setup page 25 HH MM SS 00 00 01 99 59 59 CYCLE END Setup page 25 HH MM SS 00 00 01 99 59 59 CYCLE MODE Selection page 26 Cycles 01 99 PUMP ON Setup page 24 Time Pressure or Cycles Pump ON Time HH MM SS 00 00 01 99 59 59 Cycles 01 99 only used when mode of operation cycles PUMP OFF Setup page 2...

Page 42: ...Switch Life estimate Hardware rated for 100 000 switch closures 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 ...

Page 43: ...Dimensions 313855K 43 Dimensions Mounting Hole Layout 4 8 in 122 mm 4 72 in 120 mm 3 58 in 90 85 mm 4 17 in 105 92 mm 3 23 in 82 0 mm ...

Page 44: ...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...

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