Graco 3A2960EN-D User's Manual
Contents
1. E J Controller J Capabilities gt 0 a Low Reservoir Level N switch user provided K gt o Cee Pressure or Cycle Switch for system control i co user provided TE CE mm I i e light or horn user provided FIG 2 A Main Air Supply E Ignition Switch B Filter Regulator Lubricator Assembly F High Pressure Lubricant Supply Lines B1 Filter G Injector Banks B2 Regulator H Lubrication Controller B3 Lubricator J In line Fuse C Air Solenoid Valve K Power Source D Pump Module 3A2960D Installing the Lubrication Controller AUTOMATIC SYSTEM ACTIVATION HAZARD Unexpected activation of the system could result in seri ous 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 Con troller Drill mounting holes Refer to Mounting Hole Layout Provided in the Technica2. Operating temperature range 40 F to 176 F 40 C to 80 C Storage Temperature 40 F to 176 F 40 C to 80 C 3A2960D 19 Dimensions Dimensions Mounting Hole Layout I 2x0 4 92 in 125 0 mm 5 53 in 140 0 mm 20 3A2960D Notes Notes 3A2960D 21 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 ma
3. PUMP ON page 11 PRESSURE CONTROL page 11 Pressure Cycle Time MM SS 00 01 59 59 CYCLE CONTROL Setup page 11 BACKUP TIME Setup 12 Cycles 01 99 MM SS 00 01 59 59 TIME CONTROL page 12 PUMP OFF Setup page 13 Time MM SS 00 01 59 59 Pump OFF Time HH MM 00 01 99 59 LOW LEVEL page 13 LL 01 Default single activation LL 02 Paddle Style 10 count activation Accessories Related Kits Kit No Description 24P314 GLC2200 Wiring Harness Kit 24P686 Single Connector Kit 24P687 Multiple Connector Kit 18 3A2960D Technical Data Technical Data Input Contact Power Source DC 9 30 VDC Power Consumption 1 Watt Cycle Pressure Control Input optional 9 30 VDC Normally open Pressure or cycle switch Lubrication level optional Normally open level switch closes upon low level Outputs Pump control Pump Control Voltage Power Source Voltage Pump Control Voltage Power Source Max Switching Voltage 30 VDC Max Switching Current 9A DC Min Switching Current 100 mA DC Alarm normally open Voltage Alarm Power Source Max Switching Voltage 30 VDC Max Switching Current 2A DC Protection grade IP54 for indoors and vehicle cab use Alarm Sound Pressure Level 75 dB Enclosure Material ABS Membrane Material Polyester Maximum Humidity 90 RH non condensing
4. TIME infor mation are saved The display shows the revision level The controller goes to the beginning of a PUMP OFF Cycle Operation Run Mode The controller is in Run Mode providing the following cir cumstances are present The controller is not in SETUP MODE An Alarm is not active Pressure Mode Pump ON The display indicates the amount of backup time remaining see Pressure Mode on Pr ON setup page 12 The Pressure ON LED illuminates and the pump output is enabled as long as the system is in the Pump ON state e Ifthe pressure switch input is activated before the Backup Pump On Time expires the system switches to a Pump OFF state e If the pressure switch is NOT activated before the Backup Pump On Time expires the system faults goes to the Pump OFF state and pauses until the alarm is cleared Pump ON time is shown in MM SS minutes sec onds Pressure Mode Pump OFF The display indicates the amount of time remaining in the pump OFF cycle counting down the Pump OFF time value see Programming OFF Time Duration page 12 The pump output is disabled during the Pump OFF time The Time OFF LED is illuminated as long as the system is in the Pump OFF state Pump OFF time is shown in HH MM hours minutes or MM SS if the time remaining is less than an hour 3A2960D Cycle Mode Pump ON The display alternates between the number of cycles remaining and indicates the amount of
5. amount of time remaining in the pump OFF cycle counting down the Pump OFF time value see Programming OFF Time Duration page 12 The Time OFF LED illuminates and the pump output is disabled during the Pump OFF time Pump OFF time is shown in HH MM hours minutes or MM SS if the time remaining is less than an hour Alarm Operation When an alarm situation occurs pump operation is immediately disabled the front panel Alarm LED illuminates an error code displays e an audible alarm sounds the alarm output contact activates Press the Reset button once to clear buzzer press and hold for 3 seconds to clear alarm and switch controller to OFF MODE See Alarm Types and Messages Table page 16 for additional information related to alarms and alarm mes sages 15 Setup Alarm Types and Messages Alarm Type Error Code Description Things to Check Do Refill lubrication reservoir i i Low ubneen level If low level fault occurs unexpectedly verify wiring and programming setup Low Level as t Inspect lubrication system for broken or plugged lines Confirm pump is operating correctly 71 Backup time expired prior to inspect Wirinaand switch Cycle Z J receiving programmed p g i nUMberaloyci counts Confirm that sufficient backup time was programmed for environment conditions e g slower system response in cold temperatures Verify programming Inspect lubrication sys
6. running Pump OFF LED D In RUN MODE this LED illuminates when in the OFF or RESET portion of the RUN CYCLE 3A2960D Component Identification Display E e A blinking field on the display indicates the controller is in SETUP MODE In RUN MODE numbers on the display will not blink Alarm LED F Illuminates when any alarm is detected When an alarm is active an error code displays and an audible alarm also sounds RIGHT Direction Arrow MANUAL RUN ENTER G e In SETUP MODE saves entry moves cursor in display one field to the right or to the next setup step In RUN MODE activates the pump for one com plete ON cycle if actuated during the OFF por tion of the RUN cycle UP and DOWN Direction Arrows H Press and hold both the UP and DOWN Arrow keys together for 3 seconds to enter SETUP MODE e In SETUP MODE increase or decrease number values associated with the various RUN MODES LEFT Direction Arrow RESET J In SETUP MODE moves cursor in display one field to the left In RUN MODE Pressing RESET starts a PUMP OFF cycle e In ALARM MODE Press once to clear buzzer Press and hold for 3 seconds to clear warning and switch controller to OFF MODE 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
7. E 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information 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 i
8. Instructions GRACO GLC 2200 Lubrication Controller e For controlling and monitoring an automated lubrication system Not approved for outdoor use or use in explosive atmospheres or hazardous locations Model 24N468 Important Safety Instructions Read all warnings and instructions in this manual Save these instructions ON OFF 3 ee VHH 4MM 4SS m CE PROVEN OUALITY LEADING TECHNOLOGY Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to Procedure specific risks When these symbols appear in the body of this manual or on warning labels refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable e e e e e e e EQUIPMENT MISUSE HAZARD e Misuse can cause death or serious injury e 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 com ponent See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your mat
9. M fields NOTE The MM field is a 2 digit number e A leading zero 0 must be entered in the first field if the number of minutes is fewer than 10 The highest number that can be set for the MM field value is 59 5 Repeat steps 1 4 to set the MM fields 6 Press the ENTER button to lock in the last MM field The controller automatically switches to the LOW LEVEL SETUP MODE Programming the Low Level Setting NOTE If LOW LEVEL is not used i e Low Level inputs are not connected configuring the Low Level Setting is still required The unit s default settings can be used LL 01 displays This is the default low ere rm 1 level setup when working with a stan Ltt dard normally open low level switch The unit will enter a low level fault condition after the switch input is closed for more than 1 second when the unit is in the ON portion of the RUN MODE 13 Setup Use the UP or DOWN ARROW until LL 02 displays This will set the controller up to use a pad dle style low level algorithm like the Graco G3 grease units To ensure a low level condition has been met in this mode 10 consec utive low level triggers must be detected If a low level trigger is not detected in 30 seconds of run mode the count is reset to zero J TU gt Press the ENTER button NOTE When the user exits SETUP MODE 14 An alarm sounds briefly and LED lights indicating the new programming settings and OFF
10. ashes Use the UP or DOWN ARROW to scroll through the numerals 0 9 until the desired number appears in the second cycle number field 5 Press the ENTER button After you press the ENTER button the controller saves the Cycle Con trol information and moves to setting Backup Time page 12 Time Control on ti ON Setup 1 Use the UP or DOWN ARROW to cycle through until on ti displays Lt KZ Y 2 Press ENTER 3 To set the ON time use the UP or DOWN ARROW to scroll through the numerals 0 5 until the desired number appears in the first Minutes MM field NOTE e The MM field is a 2 digit number e A leading zero 0 must be entered in the first field if the number of minutes is fewer than 10 The highest number that can be set for the MM field value is 59 4 Press the ENTER button The next MM number field to the right flashes indicating it is ready for programming 5 Use the UP or DOWN ARROW to scroll through the numerals 0 9 until the desired number appears in the second MM number field 6 Press the ENTER button The next number field to the right flashes indicating it is ready to program the Seconds SS fields 12 NOTE The Seconds SS field is a 2 digit number e A leading zero 0 must be entered in the first field if the number of seconds is fewer than 10 e The highest number that can be set for the SS field value is 59 7 Repeat steps 3 6 to set the SS fields 8 P
11. erial request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it 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 3A2960D Component Identification Keypad Display and Icons To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails A D E F G j RATE GRACO FIG 1 Pump ON LEDs A B C A Pressure Control LED In RUN MODE illuminates indicating function mode that is currently running B Cycle Control LED In RUN MODE illuminates indicating function mode that is currently running C Time Control LED In RUN MODE illuminates indicating function mode that is currently
12. l Data section of this manual page 20 2 Align junction box with predrilled holes FIG 3 a Use two screws not provided to secure junction box to mounting surface 3A2960D Installation System Configuration and Wiring The System Configuration Diagrams FIG 4 FIG 6 Sensor Wiring Diagrams FIG 8 FIG 9 and Wiring Dia grams FIG 7 on the following pages show typical Injector Series Progressive and Dual Line lubrication system configurations Refer to Table 1 2 and 3 to determine the Required Sys tem Configuration Sensor Configuration and Wiring Diagram to use to setup your system Table 1 System Configurations System Figure Page Injector 4 6 Series Progressive 5 7 Dual Line 6 8 Table 2 Sensor Wiring Configurations Sensor Figure Page Dry Contact 7 10 Source Switch 8 10 Table 3 Modes of Operation Mode Power Figure Page Time ON Time OFF DC 9 9 Cycle ON or Pressure DC 9 9 ON Time OFF Low Level Switch 9 9 Installation System Configuration Injector System Injectors Low Level Switch FIG 4 Lubrication Points Pressure Switch Pump amp Reservoir External Alarm 3A2960D Divider Valve System FIG 5 Installation Master Divider Valve Low Level Switch Pump On Off 3A2960D Installation Dual Line System Lubrication Points Reservoir Low Level Swi
13. l on the controller label also indicates the function NOTE Selection on Pr on CY or on ti designates the way the pump run time is controlled e on Pr Pressure Control reaching a specific pressure threshold measured by an external pressure switch _ D RIRE on CY Cycle Control com gt pleting a specific number of A cycles of an external lt prox cycle switch Tu Lite J e on ti Time Control a spe cific duration of time elapses 3A2960D Setup Pressure Control on Pr ON Setup 1 Use the UP or DOWN ARROW a until on Pr displays 2 Press the ENTER button 4 DI 3 Pressure control is an ON OFF selection only After you press the ENTER button the controller saves the Pressure Control informa tion and moves to setting Backup Time page 12 Cycle Control on CY ON Setup 1 Use the UP or DOWN ARROW until on CY displays Ty Wa 2 Press the ENTER button The first number displayed after the on CY is entered blinks indicating the device is ready to program the number of cycles NOTE The cycle entry is a 2 digit number A leading zero 0 must be entered in the first field if the number of cycles is fewer than 10 3 Program the cycles by pressing the UP or DOWN ARROW to move up or down through the numbers 0 9 4 When the correct first digit is displayed press the ENTER button 11 Setup The cursor automatically moves to the second number field and fl
14. n 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 MM3A2960 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 e MINNEAPOLIS MN 55440 1441 e USA Copyright 2012 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com December 2013
15. o 9 until the desired number appears in the second MM number field 4 Press the ENTER button We indicating it is ready to program the seconds fields The next number field to the right flashes and the LED lights under SS 5 Repeat steps 1 4 to set the SS seconds fields 6 After pressing the ENTER button to set the last SS field all the pro grammed ON Time information is saved lt TE The controller automatically switches to the OFF Time SETUP MODE Programming OFF TIME Duration After setting the parameters for either Pressure Pr Cycle CY or Time Ti ON Modes the OFF TIME or PUMP REST CYCLE must be set up The LED below the OFF TIME Symbol Illu minates NOTE e The HH field is a 2 digit number e A leading zero 0 must be entered in the first field if the number of hours is fewer than 10 The highest number that can be set for the HH field value is 99 3A2960D Setup To set the OFF Time 1 Use the UP or DOWN ARROW to scroll through the numerals 0 9 until the desired number appears in the first Hours HH field 2 Press ENTER We The next HH number field to the right flashes indicating it is ready for programming 3 Use the UP or DOWN ARROW to scroll through the numerals 0 9 until the desired number appears in the second HH field 4 Press the ENTER button The next number field to the right flashes indicating it is ready to program the Minutes M
16. ress the ENTER button After you press the ENTER button the controller automatically switches to the OFF TIME SETUP MODE Backup Time In both Cycle and Pressure Modes a maximum run Time Backup Time for the lubrication period must be set up If this Time expires before the lubrication is com pleted an alarm warning is triggered and the pump stops To determine the Backup Time Graco recommends the user verify the length of time it takes to complete a typi cal cycle and double that value Backup Time is setup after Cycle or Pressure Sensor Setup is complete NOTE The LED below the clock in the ON field lights indicating the Backup Time is being programmed BACKUP ON Time is set as minutes and seconds MM SS only The small flashing LED under the MM indicates you are setting minutes e The first field left side of display blinks indicating the device is ready for you to begin programming Programming Backup Time NOTE When programming a time of less than 10 min utes you must program the leading zero in the first num ber field and press the ENTER button 3A2960D 1 To set the ON Time use the UP or DOWN ARROW button to scroll through numerals 0 to 5 until the desired number appears in the first MM minutes field 2 Press the ENTER button The next MM number field to the right flashes indicating it is ready for program D ming 3 Use the UP or DOWN ARROW button to scroll through numerals 0 t
17. tch GLC 2200 Pump On Off External Alarm FIG 6 8 3A2960D Installation Wiring Diagram Modes of Operation Optional I O Wiring Diagram Used with all modes of GLC2200 Operation O O O O FIG 7 Normally open vent valve for use with Injector based systems Wiring Key Connector Identification Label PIN 1 2 3 4 5 Pin Description 1 Pump 2 Alarm 3 Low Level 4 Pressure Cycle Switch 5 Voltage Input 5 6 Pump 7 Alarm 8 Low Level 9 Pressure Cycle Switch 10 Voltage Input 3A2960D 9 Installation Sensor Wiring Configurations DRY CONTACT SWITCH SOURCE SWITCH 2 or 3 Wire Type VDC GLC 2200 I l I I 9 l I l I I 0 4 l FiG 8 VDC FIG 9 10 3A2960D Setup Entering SETUP MODE 1 Press both the UP and DOWN ARROW buttons together for three seconds NOTE e If a button is not pushed for 1 minute the controller returns to the start of an OFF cycle Setting changes are not stored unless programming is completed and setup mode is exited normally by pressing the ENTER button e A blinking dot below the HH MM SS or indi cates the field currently being programmed Programming ON Duration on Pr on CY or on ti appears on the display identi fying the function you are programming see below a Da al QN QI I I OMK e The illuminated LED below the related symbo
18. tem for broken or plugged lines Confirm pump is operating correctly i i i i i tly c n Backup time expired prior to Confirm vent valve is operating correctly Pressure 7 receiving pressure switch Inspect wiring and switch input Confirm that sufficient backup time was programmed for environment conditions e g slower system response in cold temperatures Verify programming Cycle power l Internal system error Poe enn 0 J S occurred If the system error persists contact Graco Customer Support 16 3A2960D Parts Ref Description D BOX enclosure LABEL control overlay LABEL serial name LABEL connector 3A2960D Parts Qty e ON OF HH 4MM 4SS yon t 2 gt NZ G GLC 2200 17 Troubleshooting Troubleshooting Description Problem Solution Unit does not power on or display is dim unresponsive Incorrect or loose wiring Refer to installation instructions beginning on page 4 Input voltage is out of range Confirm power source is between 9 and 30 VDC Tripped external fuse Confirm that none of the devices or wiring connected to the controller are causing a short circuit connection Replace fuse If fuse trips again con tact Graco Customer Support Program Settings Description Modes of Operation Maximum Minimum and Additional Comments
19. terials 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 PURPOS
20. time remaining in the pump cycle counting down the Backup Pump ON time value see Cycle Mode on CY ON Setup page 11 The Cycle ON LED illuminates and the pump output is enabled as long as the system is in the Pump ON state e If the Input Cycle Switch is activated the amount of times equal to the Cycle Definition variable before the Backup Pump On Time expires the system switches to a Pump OFF state e If the cycle switch is NOT activated the number of times equal to the cycle definition variable before the Backup Pump On Time expires the system faults goes to the Pump OFF state and pauses until the Alarm is cleared Pump ON time is shown in MM SS minutes sec onds Cycle Mode Pump OFF The display indicates the amount of time remaining in the pump OFF cycle counting down the Pump OFF time value see Programming OFF Time Duration page 12 The pump output is disabled during the Pump OFF time The Time OFF LED illuminates as long as the sys tem is in the Pump OFF state Pump OFF time is shown in HH MM hours minutes or MM SS if the time remaining is less than an hour Timer Mode Pump ON The display indicates the amount of time remaining in the pump cycle counting down the Pump ON time value see Time Control on ti ON Setup page 12 The Pump output is enabled Pump ON time is shown in MM SS minutes sec onds 3A2960D Setup Timer Mode Pump OFF The display indicates the
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