Graco 24B596, 24B591 User Manual

Instructions

ti14059

GLC 4400 Lubrication Controller

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.

313855H

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.

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Component Identification

Keypad, Display, and Icons

Component Identification

IG. 1

Run Mode Functions

Direction Arrows

A Up and Down Arrow Keys: Adjusts contrast. B Left and Right Arrow Keys: Adjusts brightness.

• 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

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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.

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Installation

Controller

Capabilities

Low Reservoir Level

switch (user provided)

Pressure or Cycle Switch

for system control

(user provided

Machine Counts for

System Control (user provided)

Pressure Switch or Cycle

Switch Alarm

Low Level Alarm

Remote Alarm Device

(Light or Horn)

(user provided)

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.

FIG. 2

A Main Air Supply B Filter/Regulator/Lubricator Assembly

B1 - Filter B2 - Regulator

G Injector Banks H Lubrication Controller J Model 24B591 12/24VDC Power Supply K Model 24B596 115/230VAC Power Supply

B3 - Lubricator

C Air Solenoid Valve D Pump Module E Ignition Switch F High-Pressure Lubricant Supply Lines

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Installation

jumper

motor ground

sensor ground

ground

Installing the Lubrication Controller

AUTOMATIC SYSTEM ACTIVATION HAZARD

Unexpected activation of the system could result in serious injury, including skin injection and amputation.

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.

#6 screws (not provided) to secure junction box to mounting surface.

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 (F

IG. 3, (a). Use four,

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.

1. Loosen M6 screws from (b).

2. Attach up to 3 ground wires to (b) using appropriate sized M6 ring terminal (not provided).

FIG. 3

* Parts not supplied. To maintain IP69K rating, proper

connectors must be used.

3. If more than 3 wires are used, attach necessary amount of jumpers to other adjacent screw terminals.

FIG. 4

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Installation

System Configuration and Wiring

The System Configuration Diagrams (FIG. 5 - FIG. 7), Sensor Wiring Diagrams (FIG. 8 - FIG. 10) and Wiring Diagrams (F

IG. 11 - FIG. 16) on the following pages, show typical Injector, Divider Valve and Dual Line lubrication system config-

urations.

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 (F

Table 1: System Configurations

System Figure Page

Divider Valve 5 8 Dual Line 6 9 Injector 7 10

Table 2: Sensor Wiring Configurations

Sensor Figure Page

Dry Contact 8 11 Sourcing 9 11 Sinking 10 11

IG. 17 - FIG. 19).

Table 3: Modes of Operation

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 Cycle ON or Pressure

ON/Machine Count OFF

Cycle ON or Pressure ON/Machine Count OFF

DC 13 13

AC 14 13

DC 15 14

AC 16 14

Table 4: Optional I/O Wiring Diagrams

System Mode Power Supply Wiring Diagram

Low Level Switch F

External Manual Run F

O.K. Contact Out F

Auxiliary and Low Level

Alarm Out

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DC: FIG. 18, page 16 115/230 VAC: F

IG. 17, page 15 IG. 17, page 15 IG. 17, page 15

IG. 19, page 16

Installation

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

System Configuration

FIG. 5

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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 Valves

Lubrication Points

Vent Line

Pump On/Off

Reverser

Remote Manual Run

Machine Count Swtich

Installation

FIG. 6

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Installation

GLC 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

FIG. 7

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Installation

x = sensor input 1,2,3 or 4

1 (SW +)

2 (IN (x))

3 (SEN (x))

4 (SW -)

1 (SW +)

4 (SW -)

x = sensor input 1,2,3 or 4

2 (IN (x))

3 (SEN (x))

1 (SW +)

4 (SW -)

x = sensor input 1,2,3 or 4

2 (IN (x))

3 (SEN (x))

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

FIG. 8

SOURCE SWITCH - 2 or 3 Wire Type

SINK SWITCH - 2 or 3 Wire Type

FIG. 10

IG. 9

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