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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Troubleshooting Troubleshooting Description Problem No power supplied to solenoid Power light off: Timer is not receiving power. Verify connections and verify power supply.
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
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.
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.
