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Graco 24B596 manual

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Table of contents for the manual

  • Page 1

    Instr uctions GLC 4400 Lubrication Contr oller 313855H For controlling and monito ring single-line resist ive, parallel, series pr ogressive and dual line, automatic lubricati on systems. Not for use in e xplosive atmospheres! P a rt No.: 24B591, Series C: DC P ower P ar t No.: 24B596, Series C: A C P ower Important Safety Instructions Read all war[...]

  • Page 2

    Warnings 2 313855H Wa r n i n g s The f ollo wing warnings are f or the setup , use, grounding, maintenance, and repair of this equipment. Th e e xclama- tion point symbol alerts you to a gener al warning and the hazar d symbol ref ers to procedure-specific risk. Ref er back to these wa r nings . Additional, pr oduct- specific w arnings may be f ou[...]

  • Page 3

    Component Identi fication 313855H 3 Component Identification K eypad, Displa y , and Icons Run Mode Functions Direction Arro ws A Up and Down Arro w K eys: Adjusts contr ast. B Left and Right Arro w K eys: Adjusts brightness. • Press the LEFT and RIGHT ARRO W ke ys simultaneously t o manually start a pump cycle. Keypad Icons NO TE: K eypad Icons [...]

  • Page 4

    Component Identification 4 313855H Icons The f ollo wing icons are used through out this instruction manual and on the Controller’ s Run and Setup Screens . Ref er to this tab le if you are unsure of an Icon’ s meaning. *See Field E, page 3 f or location of these Function Icons . P o wer on indicator*. When power is supplied to the Lubrication [...]

  • Page 5

    Installation 313855H 5 Installation T ypical Installation The installation shown in F IG . 2 is only a guide f or selecting and inst alling system components . Contact your Gr aco distrib utor f or assistan ce in planning a system to su it you r needs . A Main Air Supply B Filter/Regulato r/Lubri cator Assembly B1 - Filter B2 - Regulator B3 - Lubr [...]

  • Page 6

    Installation 6 313855H Installing the Lubrication Contr oller 1. Select a flat surf ace to install the Lubrication Con- troller . Dr ill mounting holes . Ref er to Mounting Hole La y out provided in the T ech nical Data section of this manua l, page 34. 2. Remove Lubrication Con tro ller cov er and align junc- tion box with predrilled holes (F IG .[...]

  • Page 7

    Installation 313855H 7 System Configuration and Wiring The System Configur ation Diagr ams (F IG . 5 - F IG . 7) , Sensor Wiring Diagr ams (F IG . 8 - F IG . 10) and Wiring Diagr ams (F IG . 11 - F IG . 16) on the f ollowing pages, sho w typical I njector , Divider V alv e and Dual Line lubrication system config- urations. Ref er to T ab le 1, 2 an[...]

  • Page 8

    Installation 8 313855H System Configuration F IG . 5 GLC 4400 External Low Level Alarm Remote Manual Run Machine Count Switch Low Level Switch Pump Reservoir Master Divider V alve Secondary Divider V alves Cycle Switch Divider V alve System External O.K. Pump On/Off External Alarm Cycle Machine Count[...]

  • Page 9

    Installation 313855H 9 F IG . 6 GLC 4400 External Alarm Cycle Machine Count External Low Level Alarm External O.K. Low Level Switch Pump Reservoir Dual Line System Cycle Switch Bi-flo V alves Lubrication Points V ent Line Pump On/Off Reverser Remote Manual Run Machine Count Swtich[...]

  • Page 10

    Installation 10 313855H F IG . 7 GLC 4400 External Low Level Alarm Remote Manual Run Machine Count Switch Low Level Switch Pump Reservoir Injector System Pressure Switch Injectors Lubrication Points V ent Line Pump On/Off External O.K. External Alarm Cycle Machine Count[...]

  • Page 11

    Installation 313855H 11 System Wiring NO TE: On an AC controller (p/n 24B596), the J7 strip is line (input ) voltage but the J6 str ip is all 24VDC. On a DC controller (p/n 24B59‘) , the J6 and J7 terminals all ca rry the input voltage. Input Sensor Wiring: DR Y CONT A CT SWI TCH SOURCE SWITCH - 2 or 3 Wire T ype SINK SWITCH - 2 or 3 Wire T ype N[...]

  • Page 12

    Installation 12 313855H Pump ON = Time; Pump OFF = Time 9 - 30VDC 100V A C/240V A C F IG . 11 *Dry Contact, F IG . 8 shown. For other config uration, see F IG . 9 or F IG . 10 . F IG . 12 16 (SW-) 15 (SEN4) 14 (IN4) 13 (SW + ) 12 (SW-) 1 1 (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[...]

  • Page 13

    Installation 313855H 13 System Wiring Pump ON = Cycle or Pr essure; Pump OFF = Time 9 - 30VDC 100V A C/240V A C F IG . 13 *Dry Contact, F IG . 8 shown. For other config uration, see F IG . 9 or F IG . 10 . F IG . 14 *Dry Contact, F IG . 8 shown. For other config uration, see F IG . 9 or F IG . 10 . 16 (SW-) 15 (SEN4) 14 (IN4) 13 (SW + ) 12 (SW-) 1 [...]

  • Page 14

    Installation 14 313855H System Wiring Pump ON = Cycle or Pressure; Pump OFF = Mac hine Count 9 - 30VDC 100V A C/240V A C F IG . 15 Dry Contact, F IG . 8 shown. For other co nfiguration, see F IG . 9 or F IG . 10. F IG . 16 Dry Contact, F IG . 8 shown. For other co nfiguration, see F IG . 9 or F IG . 10. 5A max. 16 (SW-) 15 (SEN4) 14 (IN4) 13 (SW + [...]

  • Page 15

    Installation 313855H 15 System Wiring Options All Units: Low Le vel Switch / Exter nal Man ual Run / O .K. Contact Out NO TICE Do not connec t any of the SW+ (13,9,5,1) and SW- (16,12,8,4) pins together , either direct ly or via a s witch closure. Doing so will create a shor t circuit condition which will disable and potentially damage the controll[...]

  • Page 16

    Installation 16 313855H System Wiring Options: Alarm Out 9 - 30VDC 100/240V A C F IG . 18 F IG . 19 16 (SW-) 15 (SEN4) 14 (IN4) 13 (SW + ) 12 (SW-) 1 1 (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) 1 1 OUTPUTS -PWR + J6 J7 + [...]

  • Page 17

    Setup 313855H 17 Setup When you first tur n o n power to the Lubr ication Cont rol- ler , the following identification screen displa ys. A Displa y Contrast Adjustment: UP an d DO WN Arrows can be used to ad just the displa y contrast. B Brightness Adjustment: LEFT an d RIGHT Arrows can be used to adjust th e backlight brightness. NO TE: Contr ast [...]

  • Page 18

    Setup 18 313855H 8. If the PIN Code you entered is cor rect, the System Setup Screen, shown in F IG . 22 displays . 9. If the PIN Code you entered is inco rrect, the digits flash. The Code m ust be re-entered b y repeating steps 4 and 5. NO TE: • As soon as any arro w k ey is presse d, the numer als stop flashing. • T o leav e any Setup Screen [...]

  • Page 19

    Setup 313855H 19 7. Press ENTER. 8. Select TIMER from the pull-down list. 9. Press RESET . The Ma in Screen displays. NO TE: When TIMER is selected, the Timer Icon will dis- pla y on the top right cor ner of the screen . PRESSURE Setup NO TE: Time is displa yed in HH:MM:SS . 1. Use the Ar row ke ys to mov e the cursor ov er the PUMP ON time bo x. 2[...]

  • Page 20

    Setup 20 313855H Cycl e Mode Select ion If the Cycle Mode is selected you will also be prompted to set the desired number of cycles. NO TE: A cycle is equal to two switch closure transitions at the cycle switch input. 10. Use the Arrow keys to mov e the cursor over the CYCLES field. 11. Press ENTER. 12. Use the UP/ DO WN arro ws to mov e up and dow[...]

  • Page 21

    Setup 313855H 21 If TIME is select ed: If TIME is selected y ou will al so be prompted to set the specific amount of time . 1. Use the Ar row ke ys to mov e the cursor ov er the TIME field. 2. Press ENTER. NO TE: Time is displa yed in HH:MM:SS . 3. Use the UP/DO WN arro ws to mo v e up and down through the n umbers 0-9 until the first num ber in th[...]

  • Page 22

    Setup 22 313855H 4. Use the RIGHT arro w to mo v e the cursor t o the ne xt field. Repeat st ep 3. NO TE: The maxim um number of Counts y ou can setup in this field is 9999. 5. Use the Arro w ke ys to mov e the cursor o v er the TIME field. 6. Press ENTER. NO TE: Time is displa ye d in HH:MM:SS. 7. Use the UP/DO WN arro ws to mo v e up and down thr[...]

  • Page 23

    Setup 313855H 23 Second: At P ower Up , a delay occurs, the pump is off; then the nor mal lube cycle that was in process when power w as removed, is resumed. 1. Use the Ar row ke ys to mov e the cursor ov er the PO WER UP pull-down menu. 2. F rom the pull-down menu, select OFF . 3. Press ENTER. 4. Use the Ar row ke ys to mov e the cursor ov er the [...]

  • Page 24

    Setup 24 313855H 5. F rom the pull-down menu, select ON. 6. Press ENTER. 7. Use the Arro w ke ys to mov e the cursor o v er the DELA Y TIME field. 8. Press ENTER. NO TE: Time is displa ye d in MM:SS. 9. Use the UP/DO WN arro ws to mo v e up and down through the n umbers 0-9 until the first number in the DELA Y TIME is displa y ed in the field. 10. [...]

  • Page 25

    Setup 313855H 25 10. Use the Arrow keys to mov e the cursor over the TIME ON field. 11. Press ENTER. NO TE: The time is displa yed in Seconds. 12. Use the UP/ DO WN arro ws to mov e up and down through the n umbers 0-9 until t he first number of the TIME ON y ou are creat ing is displa yed in the fiel d. 13. Use the RI GHT arro w to mov e the curso[...]

  • Page 26

    Setup 26 313855H DISPLA Y Setup 1. Use the UP/DOWN Arrow k e ys to mov e the cursor ov er DISPLA Y . 2. Press ENTER to display the DISPLA Y setup screen. Displa y Bac klight The displa y bac klight can be set to turn off after a pro- grammed amount of time . If the backlight is OFF it will turn back on when an y front panel ke y is pressed. 1. Use [...]

  • Page 27

    Setup 313855H 27 Quick Cycl e Screen Setup The Quic k Cycle screen setup is used to setup a T rou- blesho oting profile . 1. Use the Ar row ke ys to mov e the cursor ov er the CYCLES field. 2. Press ENTER. 3. Use the UP/DO WN arro ws to mo v e up and down through th e numbers 0-9 until the first number you want in th e CYCLES field is displa y ed. [...]

  • Page 28

    Setup 28 313855H Low Le vel Filtering Screen Setup The Low Le vel Filtering screen setup is used to filte r out spurio us signals from ro tating paddle ty pe low le v el sen- sors. NO TE: When using the GLC4400 with the G3 A utomatic Lubrication Pump , it is recommende d that the lo w le v el filterin g be set to G3 defaults . The NUMBER field dete[...]

  • Page 29

    Run Mode 313855H 29 Run Mode When y ou first turn the Lubrication Controller po w er on, the identification scre en shown in F IG . 53 displa ys. A Displa y Contrast Adjustment: UP an d DO WN Arrows can be used to ad just the displa y contrast. B Backlight Brightness Adjustment: LEFT an d RIGHT Arrows ca n be used to adjust the ba cklight brightnes[...]

  • Page 30

    Run Mode 30 313855H Prelube P ower Up If Prelube is enable d (page 22) , the prog rammed pre- lube sequence oc curs. If no Prelube seque nce has been selected, t he lube cycle that was in progress at po wer do wn is resumed. Pump On Ended with Time If the Pump On sequence ha s been prog rammed to be ended b y TIME: • The GLC 4400 pum p output rel[...]

  • Page 31

    Run Mode 313855H 31 Pump On Ended with Cycle Switc h Activation If the Pump On sequence has be en progr ammed to end by a Cycle Switch Activation: • The GLC 4400 pum p output relay activates (J7-3) and will stay on until the correct number of cycle s witch closures is receiv ed (J6-3) ( see Setup Menus , Cycle End Setup page 19 ). • The Pump On[...]

  • Page 32

    Run Mode 32 313855H • The GLC 4400 pum p output relay activates (J7-3) and will stay off until the correct number of counts (J6-15) o ccur (see Se tup Men us, Pu mp Off , page 20). • The Pump On LED (A) remains off during this time . • The Pump Off icon (C) disp la ys. • The Cycle L ED (B) and Machine Coun t icon (D) dis - pla y and indicat[...]

  • Page 33

    Troubleshooting 313855H 33 T r oubleshooting Pr ogram Settings Description Problem Solution Timer f ails to activ ate solenoid No pow er supplied to solenoid P ower light off: Timer is not receiving power . V er ify connec tions and veri fy pow er supply . P ower light on: V erify solenoid con- nections Solenoid f aulty Replace solenoid Timer f aul[...]

  • Page 34

    Technica l Data 34 313855H T echnical Data Input Contact P ower Source DC - model 24 B591 9 - 30 VDC P ower Source A C - model 24B596 100 V AC to 240 V AC - 50/60 Hz P ower consumpt ion 24 W atts Cycle Pressure Control Input ( optional) Normally open pressure or cycle switch Machine Count Contr ol Input (optio nal) Machine count control s witch Lub[...]

  • Page 35

    Dimensions 313855H 35 Dimensions Mounting Hole La y out 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 36

    All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. For patent information, see www.graco.com/patents. Original instructions. This manual contains Eng lish. MM 313855 Graco Headquarters: Minneapolis[...]