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 Preface
This publication is for the use of personnel responsible for installation, operation and maintenance
of the GC4000 controller as manufactured and supplied by Goyen Controls Co. Ltd.

Table of Contents Page

~ c

Principle of operation
1 .1 General overview 3
1.2 System configuration 4
1.3 Part number identification 4

Specifications
2.1 .Master Controller 5
2.2 Slave Card and Enclosures 6
2.3 Demand Controller 7

3 Installation instructions
3.1 Mounting locations -Master Controller 8
3.2 -Slave Card Enclosure 8
3.3 -Demand Controller 8
3.4 Difff~r~ntial pressure sensing lines 9
3.5 Tube cleaner connections 9
3.6 Electrical installation 10
3.7 Communication bus connections 11

4 Operating instructions
4.1 System start up procedure 12
4.2 Programming instructions 12
4.3 Cleaning system parameters 13
4.4 Digital display 13

5 Built in features
5.1 Coil malfunction 14
5.2 Coil replacement 14
5.3 External start/stop -automatic blowdown 14
5.4 High differential pressure and power
failure alarm contacts 5

a CJOYEN

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,
2
General Overview
The Goyen GC4000 controller is designed to control the cleaning system in reverse jet pulse dust
collectors.
The GC4000 offers three modes of operation:

-OFF -CONTINUOUS -DEMAND

The "off" mode provides no output to the valves and is primarily used to isolate the cleaning
system during dust collector maintenance.
When switched to "continuous" mode, the controller acts as a sequential controller, switching the
selected valve "on" and "off" while the dust collector is operating.
In "demand" mode the controller only instigates the s~quential cleaning operation of the valves
when the dust collector differential pressure reaches the "HIGH" set point. It continues to clean
until the differential pressure drops to the "LOW" set point. These set points and all other
cleaning system settings are via the digital controls located in the MASTER CONTROLLER.

Other operational features include:

The Master Controller is connected, via a single communication bus, to a series of slave cards
located inside the pilot valve enclosures{ for RCA valves) or junction boxes ( for CA valves.) This
eliminates the wasteful and costly practice of running separate cables and conduits for each
solenoid valve operator.
Up to 9 Slave Cards can be connected in series to the single Master Controller.
Each Slave ~ard has the capacity to operate up to 10 Solenoid pilot valves.
LED indicators are provided in both Master Controller and pilot Valve enclosures for visual
indication of which valve is energised.
A 5 digit LED readout is provided in the Master Controller to indicate the programmed settings
of the vari('lus functions.
Digital controls allow for accurate adjustment of the solenoid "on" and "off" times, avoiding the
'drift' commonly associated with analogue units.
A "Coil failure" feature informs the operator of a solenoid malfunction.
"Automatic Blowdown" feature allows for the cleaning cycle to continue to operate for a
programmed number of complete cycles after the dust collector fan is turned off.
An optional Demand Controller is available for Demand Cleaning, providing advantages
suchas:
-Extended bag/cartridge life
-Reduced compressed air consumption
-Improved filter efficiency.
The tube cleaner option is recommended to ensure the tubes connecting the Demand Controller
to the clean and dirty side of the dust collector are clean and functioning correctly.
Demand Controller alarm contacts alert the operator of excessively high differential pressures in
the dust collector.
 1.2 GC4000 System configuration

FIG:GC4.1
.
The hardware consists of three separate units: the Master Controller, the Slave Card Encl.osure;
and the Demand Controller.

1.3

For example:

Master Controller only Demand Controller only

110/240 V 50/60 Hz GC4100-00 0-10" W.G GC40 10-00
24-28 VDC GC4300-00 0-4" W.G GC4004-00
Demand Controller with Tube
Cleaner Option
0.10" W.G
0-4" W.G

GC401O-Q1GC4004-01
 Master Controller

Supply Voltoge 110 VAC 50/60 Hz

(:t 1 0% ) 240 VAC 50/60 Hz
24 -28 VDC

Output Voltage 24-30VDC

Fuse 500 mA for 110 VAC 250 mA for 240 VAC
(Slow Blow)"_"C"C4~"CC_c"-",&'W~'"C 2A for 24 VDC
,'" 'C", CccCC~We_~~"'~"" "~"'W?'"""'"'CC~"' "~'"C-=W~""M'W'_"e_m"

Cable Entries Location -refer to suit Cable Size

8- l.Qmm and 10-14mm
-~_c_»-"--,w"~~C --,--'w,-c" ? , ""i? ,
Automatic Blowdown Adjustable 0- 25 Cycles ,.i,c
"-,~--" --~,--~,--c C
cco.."
Enclosure Material Polycarbonate .
-~- _M__"W~~-'--'-'W_--
Enclosure Rating IP65 I NEMA 4 )
--'~__?"__m~~m__w '"W" , ..,..

Approval Rating CE IConformite Europeenne)

-~_c_~~---~_w -"~,,~~---~_& ,'--"*=,~~,
,... '?CJ'"c ~..
Mode Switch 2 Position Detent On/Off
2 Position Detent Continuous/Demand
-~---~,- -"'~---~"
1 -90,
Number of Outputs
-= ,~- --~~ -20° to +60°C
Operating Temperature
Range -4° to + 140°F
--~- ~~-"" ,-, c.~ ."
Valve "On" Time 0.03 -0.25 Seconds :J
Adjustable in 0.01 Second Steps
,w,Valve ~ c.-

"Off" Time 5 -240 Seconds

Adjustable in 1 Second Steps
=--""=.~--- c-__L.. "w_-"---~"'=-~-~.?..-
Coil Malfunction LED Indication
,-- """
Weight 1.9 kg

FIG: GC4.2
Master Controller

2.
 Slave Card and Enclosures
For Remote For Integral
Pilot Pilot
Solenoid Coil Voltage 24 VDC 24 VDC
So1enoid Coil Current A lA
Fuse 2A
Cable Entries 4mm
"""""'~~'-"~""'C""~"-'--~"
Enclosure Material Diecast Aluminium--" Polycarbonate
C'~_#"~~Y"c"'"'",~,_M..,w'- ~,~~c,,"c,"'-,, "h"c 'c
Enclosure Rating IP65 (Nema 4) IP65 (Nema 4)
'~~ '--~cV"~" c",'--c",c -~'"-,~~,- ~,." '"~""~~""=-=~--CE
Approval Rating CE (Conformite Europeenne)~~'---'-"-'-"C,",",c."Cc
(Confor mite Europeenne)
-"cc"~~' ~'""~"C"",",C""~"'"--~--"~
Number of Outputs .1 -10 1 -10
Per Slave Card

Number Of Slave Cards 9 9

" "v~.'_. ,""_-,",_~._,,_,,,,_,.

Operating Temperature -20° to +600( -20° to +600(

Range -4° to + 140°F -4° to + 140°F
Coil Operation
".c "-'~-"'.~'~"C_' ~ .,., ",~-,-
c ,-"--~-~=-=
LED Indication
"c'.o'_.~ ~---
LED Indication --~_.-
Weight 3.6 kg (max) 0.5 kg

GC4.3 FIG: GC4.4

e card mounted in diecast aluminium Pilot valve.)sure Slave card mounted in polycarbonate enclosure for
for remote pilot operation of diaphragm valves. operation of Integral Pilot diaphragm valves.

2.2
M25
2A
10
,..~.,--~-_.,--".,---,
-'.~-'-'""'"'-"-'.
 Demand Controller
Operational Voltage 24 VDC
Fuse-Cable 2A
Entries 10 -14mm
Enclosure Material
Polycarbonate
Enclosure Rating IP65 ( NEMA 4 )

Approval Rating CE (Conformite Europeenne)

Operating Temperature -20° to +60°C

Range -4° to + 140°F
Air Supply Connection 6mm Push in Fitting
for Tube Cleaner Flexible Air Line
Pressure Required: 400 -600 KPa
Differential Pressure' Tube Size 6mm OD X 4mm ID
Sensing Lines Maximum Length 30 Metres
Differential Pressure 0 -10" W.G (0 -2.5KPa)
Range
CCC'""C~"""""'."""C",
0 -4" W.G (0 -1 KPa)
cC"c

High Differential Pressure 5 amp Resistive Load

Alarm Contacts 1 amp Inductive Load
(Located in Master Controller (Max. 24Ov)
w~=.,~ "~cC',"CPCc.C'--~~-,,~--~---,
Weight 0.6 kg

FIG: GC4.5 -Demand Controller with Tube Cleaner

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--~',
~

Optional Tube'
Cleaner Assembly

,
2.2
MOUNTING lOCATION

Master Controller
The Master Controller is to be mounted vertically in an easily accessible location.
-Using the 4 mounting holes located in the corners of the box, securely fit the Master Controller
to a suitable structure
-Although the enclosure is rated IP65 (NEMA 4), suitable for weather conditions, a location
which is protected from direct rain is preferred.
-A shade cover from direct sunlight will assist in reading the LED indicators.
-Select a location where the ambient temperature is within the operating temperature range.
(refer 2.1 Specifications)
-The Master Controller does not need to be mounted directly onto the dust collector. NOTE: The
maximum cable length (from Master Controller to the last module eg: Demand Controller must
not exceed 100 metres).

Slave Card Enclosure

-The Slave Card Enclasure is to be mounted vertically (with cable glands, pilot valves on the
underside) in an easily accessible location.
-Using the 2 mounting brackets securely fit the Slave Card Enclosure to a suitable structure.
-The enclosure should be mounted in close proximity to the main diaphragm valves. The pilot
line length should not exceed 1 metre (39.4 inches).

Demand Controller
-Using the 4 mounting holes located in the corners of the
box, securely fit the Demand Controller to a suitable
structure.
-The Demand Controller is to be mounted vertically with
cable glands and tube cleaner connections on the
underside in an easily accessible location.
-The Demand Controller must be connected to the last Slave
Enclosure via the communication cable.
.The exact location of the unit will be determined by
a. The maximum communication cable length not to
exceed 100m.
b. The maximum differential pressure sensing lines are
not to exceed 30 metres.

NOTE: All parts of the GC4000 are ruggedly constructed

and will stand a moderate amount of vibration, physical
shock and handling. Normal care in handling and
installation is required.

FIG: GC4.6
) 2- \i"" ")

CI CiOYEN
 3.4 Differential Pressure Sensing lines
.Once the Demand Controller has been securely mounted, it is now necessary to connect the
pressure sensing lin~s in order for the demand cleaning option to be utilised.
.Two sensing ports are required in the dust collector. These ports are to be:
q -dirty side of the dust collector
b -clean side of the dust collector
(Refer FIG: GC4.7)
.These sensing ports are normally a female socket either 3/8/1, 1/2/1 or 3/4/1 welded to the
side of the dust collector casing.
.Using 6mm O.D., 4mm I.D. tubing, connect the clean air side of the dust collector to the /love'
connection on the underside of the Demand Controller. Connect the dirty air side of the dust
collector to the /I+ve/l connection. (Refer FIG: GC 4.7)
.Maximum differential pressure sensing line length is 30 metres.
.Make sure there are no kinks or restrictive bends in the tubing as this will affect the
performance of the Demand Controller
.All pressure sensing fittings and tubing are to be vacuum tight. Small leaks in the fittings or
tube will cause error in differential pressure readings.
NOTE: Push-in type pneumatic fittings are not suitable for this application. Compression type
fittings are recommended.

3.5 Tube Cleaner Connections

.In order for the tube cleaner to operate, it is necessary to connect a compressed air supply to
the Demond Controller
.The compressed air supply needs to be connected to the 6mm push-in fitting on the under-side
of the Demand Controller marked [P].
.Compressed air pressure required: 400-600 Kpa. (57-85 )psi
.The compressed air supply must be filtered with minimal water/moisture content.

Layout of Dust Collector

Cleon .ide
Clean
air l r:l
to "-VE" , --~Iennum --:::0
connection
,.,.,. ,.,

eJ 10".VE" '
Dirty side

connection
fl
Ii
Du,t
laden air ~
IJ~otl U iJ d tl
d8rP...,000 o~o 9:>~ 0
0 0 oCb--o 0 0 0
'{)O.oo 0
00
00 ~
~
0., 0 0 0 o.Qo
't;
000
~
o.

0"" ~ cc,6>
o~ ~o -

, to 'W
::::~~\~~'
""""'"
(~::t;
~F.I
I~'
DuSlcolleC:tionpoinl
FIG: GC 4.7

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Installation Instructions
ELECTRICAL
INSTALLATION

Master Controller
-Feed power cable (without plug) through a cable gland.
-Strip the cable sheath 35mm.
-Strip the-core 7mm:
-Feed into screw.

Active = 24'
Neutral = 0'
Active Active

Neutral Neutral

Earth

Top view of power socket AC version Top view of power socket DC version

wires and tighten cable gland.

-Select 110/240 switch to supply voltage.
-For 24 VDC version no transformer or selector switch is provided

FIG: GC 4.9 -Master Controller GC 4000

110/240
Select
Switch

Alarm -Auto
On/Off Bus Stop/Start
Power Switch Fuse Connections Connections
Socket

-Arrange
 ELECTRICAL
INSTALLATION

Communication Bus Connections

-Feed the communication bus through cable glands about 150mm (61/).
-Remove the 4 pin plug from the socket.
-Connect the cables to the 4 pin plug as outlined below in FIG: GC4.1 O.
-Replace the 4 pin plug into socket.
-Arrange wires and tighten cable gland.
-slave Card address codes need to be set in accordance with valve firing sequence. ie: 1 st
slave card to be operated set to 1, 2nd slave card to be operated set to 2, 3rd slave card to be
bperated set to 3 etc, etc until final slave card set. ( Refer to FIG: GC4.11 ) To a maximum of
nine slave cards.

1234 1234ilClJ]
Slave Card 1 L<l5JJ
1234
SlaveCard 2 ~II
1234

,;.' J
~~

Master Demand
Controller Controller
1 2 3 4 1 2 3 I.

[ill r
FIG: GC4.10

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~

FIG:GC4.1 .Slave card address

~ '/ 12-
-'l'1--
c'fi.~~

:.'.':.'...:..7:

3.7
 System Start Up Procedure
-Check all wiring to the GC4000 and corresponding equipment is correct. Refer section 3.
-Check the Slave Cards are addressed in the correct sequence.
-Check pressure sensing lines are correctly installed ensuring no kinks, restrictions or leaks.
Refer'section 3.5.
-Check compressed air supply is connected to the fitting marked ( PI. Refer section 3.5.
-Set the mains switch in the Moster Controller to " OFF ".

-Check the voltage selection switch.

-After checking all of the above, turn the mains power on.
-Set the mains switch to " ON " .

-The digital display will count down from 9 -O. CAUTION: Valves may operate.
-Programme the Moster Controller using Programming Instructions in section 4.2.
-When programming is completed the demand cleaning option may be used by selecting
"Demond II.

Progamming Instructions
NO'fE: The GC4000 is equipped with a "LOCKOUT" function to eliminate tampering of the
cleaning system operation. A simple code is required to access the cleaning system parameters.
The code is:

Press II+", Display should read" 4"

5
-_c T '=~.-
Press "SELEG " Display will read" Pl"
6

If a wrong sequence is pushed "ERR" will appear. Wait for "ERR" to disappear then start from
step 1 .

Once accessed (display reads "Pl --_") the cleaning system parameters need to be entered.
(Refer to section 4.3)

.-.
 4;3 Cleaning System Parameters
Parameter Assignment Description
Pl Electrical lion time' Electrical pulse time to operate a solenoid valve.
(0.03 -0.25 seconds in 0.01 steps.)

P2 Electrical "off time' Time between pulses. (5 80 seconds in

1 second steps).

P3 kPa or inches W.G = kPa

0

P4 low dP limit
3.0
P5 Upper dp limit
'.0
P6 Excessively high
dp limit. ~,o
P7
0'fIV
"'--~ ~~~_._~-,~~.~
P8 Automatic blowdown
.2J

--
u

4.4 Digital Display

The digital display consists of 5 x 14mm LED displays.

~
Displays 1 and 2 are used to:
During programming -Indicate cleaning
5J ..o.,-o ~
,._c.,.c'

system parameters eg: P1, P2...U1,

.""'--" .

U2 etc
When running -Indicate which solenoid is operating eg: 01, 02, 03, 04...90
-Indicate tube cleaning function ( CL )

2
~I
Displays 3, 4 and 5 are used to display
During programing -Cleaning system parameter settings eg: on times, off times etc
When running -Differential Pressure settings when Demand Controller is htted.
-If no Demand Controller is fitted displays 3, 4 and 5 will be blank.
 4.3 Cleaning System Parameters
Parameter Assignment Description
Pl Electrical "on time' Electrical pulse time to operate a solenoid valve.
(0.03 -0.25 seconds in 0.01 steps.)

P2 Electrical "off time' Time between pulses. (5 80 seconds in ~ -3/0

1 second steps).

P3

P4

P5

P6

P7

P8
,2.;

Number of outputs for eoch slave card =," (.to :-.",

Ul...U9
ie: U 1 equals number of outputs for slave card with address number 1. etc.

4.4

@
Displays 1 and 2 are used to:
During programming -Indicate cleaning system parameters eg: P1, P2...U1, U2 etc
When running -Indicate which solenoid is operating eg: 01, 02, 03, 04...90
-Indicate tube cleaning function ( CL )

,~
Displays 3, .4 and 5 are used ta display
During programing -Cleaning system parameter settings eg: on times, off times etc
When running -Differential Pressure settings when Demand Controller is htted.
-If no Demand Controller is fitted displays 3, .4 and 5 will be blank.

--
Coil Malfunction Feature --
Should a solenoid coil malfunction the Moster Controller is equipped with a LED indication.
-The "COIL FAILURE" LED will illuminate when a solenoid coil has malfunctioned.
-When this LED is illuminated the number of the coil which malfunctioned will be displayed in
displays 1 and 2. (The number displayed is the lost coil to foil)
-To ensure other coil malfunctions have not occurred the cleaning system will need to be
switched to " continuous" mode to cycle through all coils.

-If the" COIL FAILURE" LED illuminates simply note the number displayed and extinguish the
displays using the" + or -" buttons.
-Ensure a complete cycle of all valves is completed to check for other coil malfunctions.
-If multiple valves on one slave board show "Coil Malfunction" check the fuse and the
connections for that slave board.

Coil Replacement
The design of the GC4000 enables isolation of a single Slave Card to occur without interrupting
the entire cleaning system. Either by removing the fuse from the Slave Card or setting 0 (zero)
for the number of outputs in the cleaning system parameters. ego (U3 = 0) When coil
replacement has occurred, replace the fuse and check for correct operation using the Master
Controller displays.

External Start/Stop and Automatic Blowdown

FIG: GC4.12

-The GC4000

cleaning system
controller can
be started and

stopped using
these contacts.
(19 and 20)

Contacts closed
GC4000 controller will operate.

Contacts open
GC4000 controller will not operate & "FAN" is displayed.
If the Automatic Blowdown feature is programmed into the cleaning system parameters, the
GC4000 will complete the number of cleaning cycles whenever the contacts are opened.
 High Differential Pressure & Power Failure AJ_armContacts
The high differential pressure alarm relav will activate once the differer
pressure in the dust collector exceeds the ,re-set setting
in the cleaning system parameters.

15 20

klALARM

Relay conditions

.
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""- ;;'"i
'~'i"";
~~~
., ""'-~ Power on
Differential pressure OK

Power on
Differential pressure high
~

Alternatively these contacts Power off

can be used to indicate a
power failure.

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5.4
-.,
AVAILABLE INTERNATIONAllY
AUSTRALIA
Goyen Controls Co. Pty. Ltd. A.C.N. 000 168098

SYDNEY
Head Office & Main Manufacturing Plant
Telephone (02) 771 4111 Fax (02)771 5380

MELBOURNE
Telephone (03) 9383 1233 Fax (03) 9383 4247
Telephone (03) 97295355 Fax (03) 9720 6003

U.S.A.
Goyen Volve Corporation

WESTCOAST
Telephone (805) 2570566 Fax (805) 257 8990

EASTCOAST
Telephone (908) 3647800 Fax (908) 364 1356

GERMANY
Goyen Controls Deutschland
Telephone 49 (0) 2154 42 8879 Fax 49 (0) 2154 1636

NEW ZEALAND Quality

Endorsed
Goyen Controls Company
Telephone 109)829 0306 Fox (091 829 0309 ,""'100
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