Graco 332305L. G3 Max Automatic Lubrication Pump Instructions

Instructions
G3 Max Automatic
Lubrication Pump
332305L
For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For
Professional Use Only.
Not approved for use in explosive atmospheres or hazardous locations.
Part Nos., page 3
5100 psi (35.1 MPa, 351.6 bar) Pump Output Pressure
5000 psi (34.4 MPa, 344.7 bar) Maximum Working Pressure - Auto-Fill Shut Off
Important Safety Instructions
Read all warnings and instructions in this
manual. Save all instructions.
Conforms to ANSI/UL 73
Certified to CAN/CSA
Std. 22.2 No 68-09
3132066
24V and 110-240VAC Pumps ONLY.
EN
Contents
Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3
2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4
16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Understanding the Model Number . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Identification . . . . . . . . . . . . . . . . . . 9
Typical Installation . . . . . . . . . . . . . . . . . . . . . . 10
Typical Installation - With Remote Fill Manifold 11
Optional Installation - Without Remote
Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . 12
System Configuration and Wiring . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Connecting to Auxiliary Fittings . . . . . . . . . . . . . 22
Setting Pump Outlet Volume . . . . . . . . . . . . . . . 23
Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 23
Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 25
Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 29
Max Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control Panel Overview (FIG. 33) . . . . . . . . . . . 30
Programming the Max Model . . . . . . . . . . . . . . 31
PUMP OFF / REST Setup . . . . . . . . . . . . . . . . 36
DMS™ Models Only . . . . . . . . . . . . . . . . . . . . .
Storing Pump Program Settings to the
Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . .
Uploading Pump Program Settings to the Pump
Operation / Data Log . . . . . . . . . . . . . . . . . . . . . . .
System Event Log . . . . . . . . . . . . . . . . . . . . . . .
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Summary . . . . . . . . . . . . . . . . . . . . .
Technical Summary . . . . . . . . . . . . . . . . . . . . .
Advanced Programming . . . . . . . . . . . . . . . . . . . .
Models with Firmware 6.03 and later. DMS
Models with Firmware 7.07 and later. . . . . .
Models with Firmware 6.06 and later for
non-DMS models. Models with
Firmware 7.09 and later for DMS models . .
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Alarms: Firmware Versions 6.01 and Below . . . . 63
Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 63
Alarms: Firmware Versions 6.02 and Above . . . . 68
Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 68
Fault/Warning Scenarios for Firmware Versions 6.06
and Later for Non-DMS Models and 7.09 and
later for DMS Models . . . . . . . . . . . . . . . . . . . . 75
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . 80
Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 81
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
California Proposition 65 . . . . . . . . . . . . . . . . . . 86
Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 87
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 88
Graco Information . . . . . . . . . . . . . . . . . . . . . . . 88
39
39
40
41
41
42
45
47
48
55
56
58
58
332305L
Part / Model Numbers
Part / Model Numbers
The Part Number is a six-digit unique number that is only used to order the G3 Pump. The configured Model Number
identifies the distinct features of a specific G3 Pump. To help you understand each component that makes up the
Model Number see Understanding Your Model Number, page 5. The tables below shows the relationship between
each Part Number and its related Model Number.
2 Liter Models
Part
Model Numbers
96G017
96G018
96G019
96G020
96G021
96G023
96G024
96G025
96G026
96G030
96G031
96G032
G3-G-24MX-2L0L00-10CV00R0
G3-G-24MX-2LFL00-10CV00R0
G3-G-ACMX-2L0L00-1D0V0000
G3-G-ACMX-2LFL00-1D0V0000
G3-G-12MX-2L0L00-1DMVA2R3
G3-G-24MX-2L0L00-1DMVA2R3
G3-G-24MX-2LFL00-1DMVA2R3
G3-G-ACMX-2L0L00-1DMVA2R3
G3-G-ACMX-2LFL00-1DMVA2R3
G3-G-12MX-2L0L00-10C00000
G3-G-24MX-2L0L00-10C000R0
G3-G-ACMX-2L0L00-1D000000
96G035
G3-G-12MX-2L0L05-10CV0000
96G036
G3-G-24MX-2L0L05-10CV0000
96G037
96G098
96G107
96G110
96G115
G3-G-ACMX-2L0L00-1D00A000
G3-G-12MX-2L0L00-UDMVA1R2
G3-A-24MX-2L0L00-1DMVA2R3
G3-G-24MX-2L0L00-UDMVA1R2
G3-G-24MX-2LFL00-UDMVA1R2
G3-A-ACMX-2L0L00-1DMVA2R3
96G122
96G125
96G132
96G174
96G178
96G190
96G206
4 Liter Models
G3-G-ACMX-2L0L00-UDMVA1R2
G3-G-ACMX-2LFL00-UDMVA1R2
G3-A-ACMX-2L0L00-UDMVA1R2
G3-G-24MX-2L0L00-0D00A100
G3-A-24MX-2L0L00-UDMVA1R2
G3-G-24MX-24L0L07-0D00A000
Part
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Model Numbers
96G088 G3-G-24MX-4L0L00-10CV00R0
X
96G090 G3-G-24MX-4LFL00-10CV00R0
X
96G092 G3-G-ACMX-4L0L00-1D0V0000
X
96G094 G3-G-ACMX-4LFL00-1D0V0000
X
96G096 G3-G-12MX-4L0L00-1DMVA2R3
96G099 G3-G-12MX-4L0L00-UDMVA1R2
X
96G103 G3-G-24MX-4L0L00-1DMVA2R3
96G108 G3-A-24MX-4L0L00-1DMVA2R3
96G111 G3-G-24MX-4L0L00-UDMVA1R2
X
X
96G113 G3-G-24MX-4LFL00-1DMVA2R3
X
96G116 G3-G-24MX-4LFL00-UDMVA1R2
X
96G118 G3-G-ACMX-4L0L00-1DMVA2R3
X
96G123 G3-A-ACMX-4L0L00-1DMVA2R3
X
96G126 G3-G-ACMX-4L0L00-UDMVA1R2
96G128 G3-G-ACMX-4LFL00-1DMVA2R3
X
X
96G133 G3-G-ACMX-4LFL00-UDMVA1R2
X
96G141 G3-G-12MX-4L0L00-10C00000
96G143 G3-G-24MX-4L0L00-10C00000
X
96G145 G3-G-ACMX-4L0L00-1D000000
X
96G151 G3-G-12MX-4L0L05-10CV0000
96G153 G3-G-12MX-4L0L05-U0CV0100
96G155 G3-G-24MX-4L0L05-10CV0000
X
96G157 G3-G-24MX-4L0L05-U0CV0100
X
96G159 G3-G-12MX-4L0L05-00C0010M
96G160 G3-G-24MX-4L0L05-00C0010M
X
96G161 G3-G-12MX-4L0L05-U0C0010M
96G162 G3-G-24MX-4L0L05-U0C0010M
X
96G175 G3-A-ACMX-4L0L00-UDMVA1R2
X
96G181 G3-G-24MX-4L0L03-00C00100
X
96G183 G3-G-ACMX-4L0L00-1D00A000
X
96G188 G3-A-24MX-4L0L05-U0C0010M
X
96G212 G3-G-24MX-4LAL05-10CV0000
X
96G218 G3-G-12MX-4LFL00-10MVA2R3
96G232 G3-6-12MX-4L0005-10CV0000
332305L
3
Part / Model Numbers
8 Liter Models
Part
12 Liter Models
Model Numbers
Part
96G089 G3-G-24MX-8L0L00-10CV00R0
X
96G093 G3-G-ACMX-8L0L00-1D0V0000
X
96G097 G3-G-12MX-8L0L00-1DMVA2R3
96G100 G3-G-12MX-8L0L00-UDMVA1R2
96G104 G3-G-24MX-8L0L00-1DMVA2R3
X
96G109 G3-A-24MX-8L0L00-1DMVA2R3
96G112 G3-G-24MX-8L0L00-UDMVA1R2
96G119 G3-G-ACMX-8L0L00-1DMVA2R3
X
96G124 G3-A-ACMX-8L0L00-1DMVA2R3
X
96G127 G3-G-ACMX-8L0L00-UDMVA1R2
X
X
X
96G144 G3-G-24MX-8L0L00-10C00000
X
96G146 G3-G-ACMX-8L0L00-1D000000
X
96G152 G3-G-12MX-8L0L05-10CV0000
G3-G-24MX-120L00-1DMVA2R3
G3-G-ACMX-120L00-1DMVA2R3
G3-G-24MX-120L05-10CV00000
G3-G-24MX-120L05-U0CV0100
G3-A-12MX-120L08-V0C0010M
G3-A-24MX-120L08-U0C0010M
X
X
X
X
X
16 Liter Models
Part
96G142 G3-G-12MX-8L0L00-10C00000
Model Numbers
96G106
G3-G-24MX-160L00-1DMVA2R3
X
96G121
G3-G-ACMX-160L00-1DMVA2R3
X
96G166
G3-G-ACMX-160L00-1D0V0000
X
96G156 G3-G-24MX-8L0L05-10CV0000
X
96G168
G3-G-24MX-160L05-10CV0000
X
96G158 G3-G-24MX-8L0L05-U0CV0100
X
96G169
G3-G-24MX-160L05-U0CV0100
X
96G176 G3-A-ACMX-8L0L00-UDMVA1R2
X
96G185
G3-G-24MX-160L05-U0C0010M
X
96G177 G3-G-24MX-8L0L05-00C0010M
X
96G201
G3-A-ACMX-160L00-UDMVA1R2
X
96G154 G3-G-12MX-8L0L05-U0CV0100
96G219
G3-G-24MX-160L08-10CV0000
X
96G191 G3-G-24MX-8L0L05-10CV02M3
X
96G235
G3-G-ACMX-160L00-UDMVA1R2
X
96G195 G3-A-24MX-8L0L05-U0C0010M
X
96G252
G3-G-12MX-160L00-UDMCA1R2
96G197 G3-G-ACMX-8LFL00-1DMVA2R3
X
96G209 G3-G-ACMX-8LAL00-1DV00000
X
96G215 G3-G-24MX-8LAL05-10CV0000
X
96G216 G3-G-24MX-8L0L08-10CV00000
X
96G186 G3-A-12MX-8L0L05-U0C0010M
4
96G105
96G120
96G164
96G165
96G231
96G246
Model Numbers
332305L
Part / Model Numbers
Understanding the Model Number
Use the Code Sample provided below to identify each component’s location in the Model Number. The options for
each component that make up the code are provided on the lists below.
NOTE: Some pump configurations are not available. Contact Graco Customer Service or your local Graco distributor
for assistance.
G
3
-
G
-
Code Sample:
a
a
M X
b b
-
G3 - G = Identifies pump as being a G3; G = Grease
G3 - A = Identifies pump as being a G3; A = Oil
Code aa: Power Source
•
•
•
c
d
e
•
•
•
•
•
•
•
MX = Max (Cycle) Control
-
g
h
i
j
k m n
p
L = Low Level with Controller
0 = No Low Level monitoring
00 = No Options
03 = Powered Alarm Contact
05 = 5 Pin CPC power cable
07 = No Power Cord
08 = Normally open vent valve with alarm,
manual run, and low level in CPC
Code g, h, i, j, k, m, n, p
NOTE: Codes g - p relate to a specific location on the
G3 pump. See FIG. 1 for these locations.
2L = 2 Liters
4L = 4 Liters
8L = 8 Liters
12 = 12 Liters
16 = 16 Liters
•
•
•
•
•
•
•
•
•
Code d: Follower Plate Installed
•
•
•
f
Code e: Low Level Option
Code cc: Reservoir Capacity (Liters)
•
•
•
•
•
f
Code ff: Options
12 = 12 Volts DC
24 = 24 Volts DC
AC = 100 - 240 Volts AC
Code bb: Operation Control
•
c
F = Follower Plate Installed
0 = No Follower Plate
A = Auto-Fill Shut Off
C = CPC
D = DIN
1, 2, 3 = Sensor Number
R = Remote Manual Run
M = Machine Count
A = Alarm Output
V = Vent Valve
0 = Not populated
U = USB Port
DMS™ Model
g
h
k
m
p
i
j
n
FIG. 1
332305L
5
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 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.
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
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local 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.
• 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 material, request MSDS from distributor or retailer.
• 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 manufacturer’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.
6
332305L
Warnings
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
PRESSURIZED EQUIPMENT HAZARD
Over-pressurization can result in equipment rupture and serious injury.
•
•
A pressure relief valve is required at each pump outlet.
Follow Pressure Relief Procedure in this manual before servicing.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or
property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.
• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s SDSs and recommendations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes
but is not limited to:
• Protective eye wear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer
332305L
7
Installation
Installation
Unpacking
•
Use designated mounting holes and provided
configurations only.
NOTICE
•
Always mount the G3 oil models upright.
Observe precautions for handling electrostatic sensitive devices. Touch ground before handling pump.
•
If the G3 grease model is going to be operated
in a tilted or inverted position for any period of
time, you must use a model that includes a follower plate, otherwise the G3 must be mounted
upright. Refer to your model number to confirm
if a follower plate was installed on your pump.
See page 5, Understanding the Model Number
to identify this character in your model number.
•
Use the three fasteners (included) to secure the
G3 to the mounting surface.
2. Unseal the box and inspect the contents carefully.
There should not be any damaged parts.
•
3. Compare the packing slip against all items included
in the box. Any shortages or other inspection
problems should be reported immediately.
Some installations may require an additional
reservoir support bracket. See Table below for
bracket information.
•
In high vibration environments, additional isolation at mounting point is necessary.
•
AC pumps are not recommended when high
vibration or shock is present.
The pump module was carefully packaged for shipment
by Graco. When the package arrives, perform the following procedure to unpack the units:
1. Inspect the shipping box carefully for shipping
damage. Contact the carrier promptly if damage is
discovered.
Choosing an Installation Location
Part No Description
571159 Reservoir bracket and strap
125910 L-Bracket for pump
127665 USP to G-Series mounting bracket
AUTOMATIC SYSTEM ACTIVATION HAZARD
132187 Isolator mounting kit
If the system is equipped with has an automatic timer
(user supplied) that activates the pump lubrication
system when power is connected or when exiting the
programming function, unexpected activation of the
system could result in serious injury, including skin
injection and amputation.
Before you install or remove the lubrication pump
from the system, disconnect and isolate all power
supplies and relieve all pressure.
8
•
Select a location that will adequately support
the weight of the G3 Pump and lubricant, as
well as all plumbing and electrical connections.
•
Refer to the mounting hole layouts provided in
the Mounting Pattern section of this manual,
page 87. No other installation configuration
should be used.
332305L
Installation
Component Identification
A
N
L
M
Oil Models
Grease Models
DMSTM Models
Grease Models with Follower
Plate
P
E
I
D
F
R
J
B
H
96GXXX
G3-G-24NC-2L0A00-L0C00000
Auto-Fill Shut Off Models
FIG. 2:
Key:
A
B
C
D
E
F
G
H
I
J
K
Reservoir
Pump Element (1 included. Can accommodate 3 total)
Pressure Relief Valve (Not shown. Not included / required for
each outlet - Available from Graco. See Parts, page 83.)
Zerk Inlet Fill Fitting (1 included / grease models only)
Pump Outlet Plug (2 included)
Volume Control Spacers (2 included. More spacers = less
output volume per stroke) (also see FIG. 21, page 23)
Fuse (DC models only - Not included, not shown. Available
from Graco. See Parts, page 84.)
Control Panel
Power / Sensor Panel (both sides; only one side shown)
Part Number / Model Number example only shown, (see
pages 5, Understanding the Model Number, for details)
Power Cord (not shown)
332305L
L
N
P
Follower Plate (grease models only / not available on all
grease models)
Vent Hole for Follower Plate (grease models only / not
available on all grease models)
Fill cap (oil models only)
USB Port (DMS™ Models only)
R
Auto-Fill Shut Off
M
9
Installation
Typical Installation
Series Progressive Divider Valve Installations
B
D
E
A
F
C
FIG. 3
Injector Installations
E
H
F
B
D
G
A
C
FIG. 4
A
B
C
D
E
10
Connected to fused power source
Pressure relief valve (Not included/required for each outlet
- user supplied. See Parts, page 83)
- Cycle indicator sensor cable (Divider Installations)
- Pressure switch cable (Injector Installations)
- Series progressive divider valves (Divider Installations)
- Injectors (Injector Installations)
To lube points
F
G
H
- Proximity Switch (Divider Installations)
- Pressure switch (Injector Installations)
Vent valve (Not included / available from Graco. See
Parts, beginning on page 82.)
Return to reservoir
332305L
Installation
Typical Installation - With Remote Fill Manifold
The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor
for assistance in planning a system to suit your needs.
R
N
B
F
H
J
C
D
T
S
Q
P
M
K
A
E
L
FIG. 5
Key:
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
G3 Pump
Auto-Fill Shut Off Valve
Auto-Fill Inlet
G3 Reservoir
Remote Fill Reservoir
Remote Fill Pump
Supply Hose (user supplied)
Air Supply to Refill Pump
Supply Hose (user supplied)
Pressure Relief Valve
Drain Hose
Fill Coupler/Inlet (quick disconnect)
Fill Manifold
Fill Manifold Outlet
Fill Manifold Vent Port
Pressure Gauge
Pressure Regulator and Gauge
Pressure Relief Knob
 To relieve the stall pressure in the fill line a fill manifold
(N) must be installed in the system.
332305L
11
Installation
Optional Installation - Without Remote Fill Manifold
The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor
for assistance in planning a system to suit your needs.
NOTE: The remote filling station pump stalls (dead-heads) when the reservoir is full. If the pump does not stall
(dead-head) there is a leak in the system.
B
F
H
U
J
C
S
V
D
Y
L
A
L1
E
L2
W
FIG. 6
Key:
A
B
C
D
E
F
H
J
L
12
G3 Pump
Auto-Fill Shut Off Valve
Auto-Fill Inlet
G3 Reservoir
Remote Fill Reservoir
Remote Fill Pump
Relief Valve
Supply Hose (user supplied)
Drain Tube
L1 Option - To reservoir
L2 Option - To overflow container
S
U
V
W
Y
Pressure Regulator and Gauge
Pressure Relief Valve
Quick Disconnect
Overflow Container
Supply Hose Pressure Relief Valve
 To relieve the stall pressure in the fill line a ball valve
(Y) must be installed in the system.
332305L
Installation
System Configuration and Wiring
Grounding
Fuses
NOTICE
Fuses (user supplied) are required on all DC models. To avoid equipment damage:
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
Improper installation of the grounding conductor may
result in a risk of electric shock. This product must be
installed by a qualified electrician in compliance with
all state and local codes and regulations.
it must be installed by a qualified electrician or serviceman.
•
it must be connected to a grounded, permanent wiring system.
If an attachment plug is required in the end use
application:
•
it must be rated for the product electrical specifications.
•
it must be an approved, 3-wire grounding type
attachment plug.
•
it must be plugged into an outlet that is properly
installed and grounded in accordance with all local
codes and ordinances.
•
when repair or replacement of the power cord or
plug is required, do not connect the grounding wire
to either flat blade terminal.
332305L
Never operate G3 Pump DC models without a
fuse installed.
•
A fuse of the correct voltage must be installed in
line with the power entry to the system.
Fuse Kits are available from Graco. The following Table
identifies the correct fuse to use for your input voltage
and the corresponding Graco Kit number.
If the product is permanently connected:
•
•
Input Voltage
Fuse Value
Graco Kit No.
12 VDC
7.5 A
571039
24 VDC
4A
571040
Recommendations for Using Pump in
Harsh Environments
•
Use pump with CPC style power cable.
•
If using a DIN style power or alarm harness with a
right angle mating connector, make sure the connector does not exit the unit in the UP direction.
•
Use a corrosion preventative electrical grease on all
contacts.
13
Installation
Alarm Output and Remote Illumination Response
The following tables include graphical representations of the connector as it appears on the unit, a pin-out associated
with the connector and a typical installation wiring diagram. An internal representative wiring diagram is included
where it is deemed useful.
Wire colors provided on these pages only refer to the power cable provided by Graco with this product.
See Advanced Menu Options A7, A9, or A11 to modify the behavior of the alarm output or low level output.
Alarm Output
(via DIN alarm relay
connector)
Unit in OFF Mode
Unit in ON Mode
Deactivated (off)
Deactivated (off)
Warning Condition
Activated (on)
Fault Condition
Toggles On and Off once
per second
Standard Remote
Illumination
(via 5 wire CPC power
cable)
Off
On
Toggles On and Off once
per second
Toggles On and Off once
per second
Tri-Color Remote
Illumination
(via M12 Connector)
Off
Green
Yellow
Red
Outputs (“08” option) (via 5 wire CPC)
Pin 4
Alarm
Low Level Warning
Low Level Fault
14
Activated (On)
Toggles On and Off once per second
Pin 7
Low Level
Activated (On)
Activated (On)
332305L
Installation
Alarm Relay Response
Output Tied to Common
No Faults or
Warnings
Warning
(Advanced
Programming
Setting A11 OFF)
Fault
(Advanced
Programming A7
OFF)
Fault
(Advanced
Programming
Setting A7 ON)
N.O.
N.C.
N.O.
N.C.
N.O.
N.C.
1 second
N.O.
N.C.
Wiring and Installation Diagrams
The following Table identifies the wiring and installation diagrams provided in this manual.
Diagram
Page #
Power DIN AC
16
Power DIN DC
16
Power CPC DC
17
Inputs (M12)
18
Vent Valve Outputs
19
Alarm Outputs
19
Illuminated Manual Run Input
332305L
Symbol
Kits: 571030, 571031,
571032, 571033
15
Installation
Power DIN AC - 15 foot: Part No.
16U790
Power DIN DC - 15 foot
Pin and Related Wire Color (FIG. 8)
Pin and Related Wire Color (FIG. 7)
Pin
Pin Name
Color
1
2
3
Line
Neutral
Not Used
Black
White
Not Used
Pin
Pin Name
Color
1
2
3
-VDC
+VDC
Not Used
Black
White
Not Used
Not Used
Green
4
Ground
Green
4
FIG. 7
FIG. 8
16
332305L
Installation
Power CPC DC -2 Wire
Power CPC DC - 5 Wire
Part No.: 127783: 15 ft. (4.5 m)
Pin and Related Wire Color (FIG. 9)
Pin
Pin Name
Color
1
2
3
4
5
6
7
Not Used
-VDC
+VDC
Not Used
Not Used
Not Used
Not Used
Not Used
Black
White
Not Used
Not Used
Not Used
Green
Part No.: 127780: 15 ft (4.5 m)
Part No.: 127781: 20 ft (6.1 m)
Part No.: 127782: 30 ft (9.1 m)
An Illuminated Remote Run Button Kit: 571030, 571031
for starting a manual run cycle if used in conjunction
with a 5-wire CPC cable, is available from Graco. Contact your local Graco distributor or Graco Customer Service for additional information about these kits.
Pin and Related Wire Color (FIG. 10)
Pin
Pin Name
Color
1
2
3
4
Not Used
-VDC
+VDC
LIGHT
Manual Run
Switch
Not Used
Not Used
Not Used
Black
Red
White
5
6
7
Orange
Not Used
Green
FIG. 10
FIG. 9
332305L
17
Installation
Pin and Related Wire Color (FIG. 11)
Wiring for “08” Option
CPC Pin
Pin Name
Wire Color
1
2
3
4
5
6
7
Not Used
-VDC/Com
+VDC
Alarm
Manual
Not Used
Low Level Warning
Not Used
Black
Red
White
Orange
Not Used
Green
Inputs (M12)
See Technical Data, page 85 for ratings.
FIG. 12
FIG. 11
18
332305L
Installation
Vent Valve Outputs
Alarm Outputs
See Technical Data, page 85 for ratings.
DC example shown. See Technical Data,
page 85 for ratings.
FIG. 13
FIG. 14
1
1.
332305L
19
Installation
Part No. 124333: Cable Pin Out (M12) for 5m
cable
Part No. 124300: Male Flying Lead Pin Out
(M12)
Wire Colors (FIG. 15)
Wire Colors (FIG. 16)
Item No.
Color
1
2
3
4
Brown
White
Blue
Black
Item No.
1
2
3
4
Color
Brown
White
Blue
Black
FIG. 16
FIG. 15
Part No. 124301: 4 Pin (M12) Female Field
Wireable Connector for 6-8 mm Cable
FIG. 17
20
332305L
Installation
Part No. 124594: 4 Pin (M12) Male Field
Wireable Connector for 6-8 mm Cable
FIG. 18
NOTE: Field wireable connectors are for sensors with
integrated cable.
Part No. 124595: 5 Pin (M12) Male Field
Wireable Connector for 8-11 mm Cable
FIG. 19
NOTE: Field wireable connectors are for sensors with
integrated cable.
332305L
21
Setup
Setup
Connecting to Auxiliary Fittings
Pressure Relief
Follow the Pressure Relief Procedure whenever
you see this symbol.
NOTICE
Do not attach unsupported equipment to auxiliary fittings such as fill ports and pump element. Attaching
unsupported equipment to these fitting can result in
irreparable housing damage.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
Relieve pressure in system using two wrenches
working in opposite directions on pump element and
pump element fitting to slowly loosen fitting only until
fitting is loose and no more lubricant or air is leaking
from fitting.
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume.
•
Always use two wrenches working in opposite
directions when connecting anything to pump element or auxiliary fittings. See FIG. 20 for an example.
•
Torque pump element fittings to 50 in. lbs (5.6
N•m).
•
When connecting pump element into housing
torque to 50 in. lbs (5.6 N•m).
Pressure Relief Valves
To prevent over-pressurization, which can result in
equipment rupture and serious injury, a pressure
relief valve appropriate for the lubrication system
must be installed close to every pump outlet to alleviate unintended pressure rises in the system and protect the G3 pump from damage.
•
Only use a pressure relief valve that is rated for
no more than the working pressure of any component installed in the system. See Technical
Data, page 81.
•
Install a pressure relief valve close to every pump
outlet; before any auxiliary fitting.
NOTE: A pressure relief valve can be purchased from
Graco. See Parts, page 83.
FIG. 20
22
332305L
Setup
Setting Pump Outlet Volume
NOTE:
•
Before making any adjustments to pump volume,
Relieve Pressure following procedure on page 22.
•
Only use Graco supplied spacers to control output
volume.
1. Use a wrench to turn pump element counter-clockwise to loosen. Do not remove entire pump element.
Only back pump element out enough to allow
spacer to be slid on or off.
2. If needed, remove or insert spacers to achieve
required pump output volume. A tool may be
needed to facilitate removal.
FIG. 21
Loading Grease
To ensure optimal performance from the G3:
•
Only use NLGI #000 - #2 greases appropriate for
your application, automatic dispensing, and the
equipment’s operating temperature. Consult with
machine and lube manufacturer for details.
•
The reservoir can be filled using a hand operated
pump, pneumatic pump or electric transfer pump.
•
Do not overfill (FIG. 24).
•
Do not operate G3 without reservoir attached.
Pump volume control is set using either no (0) spacers, 1 or 2 spacers (FIG. 21).
Do not use more than 2 spacers to adjust output volume.
Output Volume / Minute
No. Spacers
cubic inches
cubic cm
2
0.12
2
1
0.18
3
0
0.25
4
NOTE:
•
The amount of dispensed volume can vary depending on external conditions such as lubricant temperature and back pressure from downstream
connections.
•
Use of these volume adjustment in conjunction with
setting the ON time of the pump will allow for control
of the output volume.
•
Use these volume adjustments as a starting point
and adjust as necessary to ensure desired lubrication dispense.
3. Tighten pump element fitting. Torque fitting to 50 in.
lbs (5.6 N•m).
332305L
NOTICE
•
Always clean inlet fitting (D) (FIG. 22) with a
clean dry cloth prior to filling reservoir. Dirt
and/or debris can damage pump and/or lubrication system.
• Care must be used when filling the reservoir
using a pneumatic or electric transfer pump to
not pressurize and break the reservoir.
D
FIG. 22
23
Setup
Models without a follower plate:
Models with a follower plate:
1. Connect fill hose to inlet fitting (D) (FIG. 23).
1. Connect fill hose to inlet fitting (D) (FIG. 23).
E
2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from
forming in grease.
To start the pump press the manual run
button.
3. Fill reservoir with grease until seal of
follower plate breaches the vent hole (FIG. 25) and
the majority of air is expelled from the reservoir.
D
FIG. 23
2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from
forming in grease.
To start the pump press the manual run
button.
Vent Hole
3. Fill reservoir with NLGI grease to max
fill line.
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
FIG. 25
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
Changing Greases
When changing greases, always use compatible fluids
or greases.
Max Fill Line
FIG. 24
4. Remove fill hose.
24
332305L
Setup
Auto-Fill Shut Off
Loading Grease
To ensure optimal performance from the G3:
•
Only use NLGI #000 - #2 greases appropriate for
your application, automatic dispensing, and the temperature. Consult with machine and lube manufacturer for details.
•
Do not overfill.
•
Do not operate G3 without reservoir attached.
COMPONENT RUPTURE HAZARD
The maximum working pressure of each component
in the system may not be the same. To reduce the
risk of over-pressurizing any component in the system, be sure you know the maximum working pressure of each component. Never exceed the
maximum working pressure of the lowest rated component in the system. Over-pressurizing any component can result in rupture, fire, explosion, property
damage and serious injury.
NOTICE
Care must be used when filling the reservoir using a
pneumatic or electric transfer pump to not pressurize and break the reservoir.
Changing Greases
When changing greases, always use compatible fluids
or greases.
Regulate input pressure to the remote fill pump so
that no fluid line, component or accessory is over
pressurized.
Remote Fill with Remote Fill Manifold
The reference letters used in the following instructions
refer to the Typical Installation diagram, page 11.
The Auto-Fill Shut Off is used for refilling the G3 reservoir in an automatic lubrication system. As fluid is added
to the reservoir, it pushes the plate valve up to the top of
the reservoir. The plate valve then pushes the valve pin
and closes the inlet fluid path.
The fill valve is used to relieve pressure in the refill line
and to reset the Auto Fill Shut Off. See Fill Valve instruction manual 333393. Graco fill valve, part no. 77X542 is
available. Contact your local Graco distributor.
When the fluid refilling path closes, the refilling line pressurizes and brings the refilling pump to a pressurized
stall condition.
1. Pull out and hold the Pressure Relief Knob (T) long
enough to relieve line pressure between Fill Manifold (N) and Auto-Fill Shut Off Valve (B).
NOTE: The operator must monitor system while filling
the reservoir to prevent overfilling.
2. Verify the Auto-Fill Shut Off (B) pin is down, indicating it is reset (FIG. 26).
pin
down
The remote filling station pump stalls (dead-heads)
when the reservoir is full, causing the supply system
pressure to rise to the maximum output pressure
of the filling station pump. To help prevent equipment
damage or serious injury caused by pressurized fluid,
such as skin injection or injury from splashing fluid,
always use a remote filling station pump with a maximum output pressure of 5100 psi (35.1 MPa,
351.6 bar) and use supply hoses with a minimum
pressure rating of 5100 psi (35.1 MPa, 351.6 bar).
FIG. 26
3. Remove yellow Dust Cover from Fill Coupler (M).
332305L
25
Setup
4. Connect Supply Hose (J) between the Remote Filling Station Pump (F) and Fill Coupler port marked
with an “I”.
5. Start Remote Filling Station Pump (F).
6. When the G3 Reservoir (D) is filled:
•
the Remote Filling Station Pump (F) stalls
(dead-heads),
•
the Auto-Fill Shut Off (B) pin pops up as shown
in FIG. 27,
•
the Pressure Gauge (R) rises to the fill pump’s
set pressure.
NOTE: If the pump does not stall (dead-head) there is a
leak in the system.
Remote Fill without Remote Fill Manifold
The reference letters used in the following instructions
refer to the Typical Installation diagram, page 12.
1. A supply hose pressure relief valve (Y) and overflow
container (W) (for collecting excess fluid that drains
during pressure relief) must be installed in an easily
accessible location between the remote filling station pump (F) and the Auto-Fill Shut Off (B). This
pressure relief valve is used to relieve pressure in
the refill line and to reset the Auto-Fill Shut Off. See
Typical Installation, starting on page 12.
A Pressure Relief Kit: 247902 is available from
Graco. Contact your distributor or Graco Customer
Service for additional information about this kit.
2. Connect Supply Hose (J) at Quick Connect (V).
pin
up
3. Turn on remote filling station pump (F) and fill the
G3 reservoir (D) until the indicator pin on the
Auto-Fill Valve pushes up as shown in FIG. 28. The
pressure in the refill pump (F) builds and the pump
stalls.
pin
up
FIG. 27
7. Turn off the Remote Filling Station Pump (F).
NO
8. Pull out and hold the Pressure Relief Knob (T) long
enough to relieve line pressure between Fill Manifold (N) and Auto-Fill Shut Off Valve (B) and
between Remote Filling Station Pump (F) and Fill
Manifold (N).
NOTE: The length of time it takes to vent varies depending on the system design and installation. In some
installations it may be necessary to repeat Step 8 to
ensure pressure is relieved.
9. Disconnect Supply Hose (J) at Fill Coupler (M).
FIG. 28
4. Turn off the air supply (H) to pump (F).
5. Relieve remote filling station pump pressure using
the following Remote Filling Station Pressure Relief
procedure:
10. Replace yellow Dust Cover over Fill Coupler (M).
26
332305L
Setup
Remote Filling Station Pressure Relief
Filling Oil Unit
The reference letters used in the following instructions
refer to the Typical Installation diagrams starting on
page 10.
•
The following Pressure Relief Procedure is only
used with the Auto-Fill Shut Off Valve to relieve
remote filling station and lubricant supply line
pressure.
Only use oil appropriate for your application, automatic dispensing, and the equipment’s operating
temperature. Consult with machine and lube manufacturer for details.
•
Do not overfill (FIG. 30).
•
Do not operate G3 without reservoir attached.
•
Only use oils with viscosity at least 40 cSt.
a
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
a. To relieve pressure between the Refill Pump (F)
and Auto-Fill Shut Off (B), open ball valve (bv)
(FIG. 29). Pressure will be released and excess
fluid will drain out of the drain tube (L) and into
the lubrication overflow container (W).
b
FIG. 30
1. Remove fill cap (a).
2. Pour oil into reservoir to max fill line (b).
3. Replace fill cap. Hand tighten cap, securely.5
Y
L
W
FIG. 29:
b. Close supply hose pressure relief valve (Y)
when all pressure has been relieved.
6. Disconnect the supply hose (J) from Quick Connect
(V).
332305L
27
Setup
Priming
2. Only run pump until air is no longer dispensed with
the lubricant coming out of element fitting (FIG. 32).
NOTE: It is not necessary to prime pump every time
pump is filled with lubricant.
Pump only requires priming the first time it is used or if it
is allowed to run dry.
1. Loosen pump element fitting (FIG. 31).
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume
FIG. 32
3. Tighten pump element fitting using two wrenches
working in opposite directions (FIG. 31).
FIG. 31
28
332305L
Quick Setup Guide
Quick Setup Guide
!"#$ ""
!
%#
'
(&
&
) *
&+
""
!
332305L
!"#$ %#
29
Max Model Setup
Max Model Setup
Control Panel Overview (FIG. 33)
NOTE: Programming instructions begin on page 31.
OFF TIME/BACKUP TIME
ON TIME/BACKUP TIME
•
•
•
•
DISPLAY
LED lights when ON
Time/Backup Time is running.
Display shows time as MM:SS
(minutes and seconds).
i.e., 08:30 is 8 minutes: 30 seconds.
Sets the limits for the amount
of time to complete a cycle or
build up pressure before a
warning is activated.
Counts down from a set time to
zero.
•
•
•
A blinking LED under HH, MM, SS
or ## identifies type of measurement
unit you are setting; i.e., HH is
hours.
A blinking number on the display
indicates the G3 is in SETUP
MODE.
In RUN MODE displayed numbers
count up or down. See Time ON and
Time OFF.
•
LED lights when OFF
Time/Backup Time is used to control Pump OFF function.
Value is entered in HH:M.
•
•
Displays in HH:MM (hours and
minutes) when > 1 hour.
Times pump rest between cycles.
•
•
Counts down from set time to
zero.
Can be set up to use as a backup
for Machine Count control.
•
CYCLE / PRESSURE SETUP
•
Sets either Cycle (C) or Pressure
(P) Monitoring limits for up to 3
sensors.
Each sensor is set up and controlled independently.
All three LEDs blink if the vent
valve output is on.
•
•
ALARM ICONS
LED next to icon lights when a
fault / warning event occurs
during a run cycle. See page 63
for a complete description of
these alarm scenarios.
MACHINE COUNT
•
PIN ICON
LED lights when Machine Count
is used to control Pump OFF
function.
Counts independent machine
operations with a sensor to control Pump Off duration.
Time OFF function can be used
as a backup for Machine Count.
•
•
•
•
LED next to icon lights indicating PIN is required to
enter setup.
In SETUP MODE LED
lights when setting up the
PIN.
PRELUBE
LED next to icon lights indicating LED lights when Prelube
function is enabled.
LEFT DIRECTION ARROW /
RESET
•
•
•
•
In SETUP MODE: moves cursor
in display one field to the left.
In RUN MODE: single press
clears warning.
In RUN MODE: pressing for one
second ends run cycle if no
warnings.
In ALARM MODE: pressing and
holding for 3 seconds clears
fault / warning and switches
cycle to OFF MODE.
UP and DOWN ARROW
RIGHT DIRECTION ARROW /
MANUAL RUN / ENTER
•
•
•
Hold both the UP and DOWN ARROW buttons down together for 3 seconds to enter
SETUP MODE.
In SETUP MODE: increases or decreases
number values shown in display.
•
In SETUP MODE: saves
entry, moves cursor in display
one field to the right or to the
next setup step.
In RUN MODE: starts a manual run cycle.
FIG. 33
30
332305L
Max Model Setup
Programming the Max Model
Checking the Firmware Version
To check the firmware version installed on the pump:
1. Remove power to the pump by disconnecting the
power cable from the connection.
2. Reconnect the power cable to the power connection.
This creates a power cycle and the firmware version
displays on the screen during the first few seconds
of power up. See FIG. 34.
The unit should be powered up in OFF mode. If the unit
powers up in ON mode and has not been primed, hold
the reset button located on the control panel (example
shown on the right) for 1 second to move to the OFF
mode.
NOTE:
•
A blinking number on the display indicates the G3 is
in SETUP MODE.
•
In RUN MODE numbers on the display do not blink.
•
After 60 seconds of no activity, the device returns to
RUN MODE in the OFF Time cycle and the OFF
Time restarts counting down the total programmed
amount of time. It does not resume the countdown
from the point where the cycle was interrupted when
you entered SETUP MODE.
Entering Setup Mode
Press both the UP and DOWN
ARROW buttons together for 3
seconds to enter the SETUP
MODE.
NOTE: If the lock LED is
lit after entering Setup
Mode and four 0000’s
are displayed, the unit
has a PIN Code lock out
enabled. See the following section: Entering a
PIN Code to Access
Setup Mode.
Entering a PIN Code to Access Setup Mode
FIG. 34
Powering Units With Controllers
By default, units with controllers are set to
operate in a timed mode:
FIRMWARE Versions MAX 0506 or
Earlier, DMS 0709 or Earlier:
1 minute of ON time and 8 hours of OFF time.
Later FIRMWARE Versions:
5 minutes of ON time and 1 hour of OFF time.
332305L
The G3 controller does not require a user to provide a
PIN code to access the programming features of the
unit. However, Graco understands that some users may
want to protect the programming settings and therefore,
an option for adding PIN Code authorization is available.
The instructions for setting up PIN Code Authorization
are provided in the Advanced Programming section of
this manual. See page 50.
To enter the PIN Code:
1. Press both the UP and
DOWN ARROW buttons for 3
seconds.
31
Max Model Setup
2. The LED next to the LOCK ICON on
the display lights and the 4 zeros
appear on the display indicating the
system requires a PIN Code entry to run the G3 in
SETUP MODE.
3. The cursor is automatically
positioned to enter the first
character of the PIN Code.
Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.
4. Press the ENTER button to set the number. The cursor automatically moves to
the next number field.
5. Repeat steps 3 and 4 for each PIN Code prompt
field.
2. Press the ENTER button to set the
decade number. The cursor automatically moves to the next field, the
year number.
3. Use the UP and DOWN arrow buttons to move up and down through
the number 0-9 until the number
for the current year is displayed in
the field.
4. Press the ENTER button to set the
year number.
The 3-character month displays indicating the G3 is
now ready to program the month.
Enter the Month:
If the PIN Code you entered is correct, the first editable
character on the display will flash.
NOTE: A blinking field on the display indicates the G3 is
in SETUP MODE. In RUN MODE numbers on the display will not blink.
DMS™ Equipped Models Only
1. Set the 3 character month by using
the UP and DOWN ARROW buttons to move up and down through
the list of months until the current
month is displayed in the field.
NOTE: Set the real time clock prior to plugging the USB
flash drive into the pump.
2. Press the ENTER button to set the
month.
Setting the Real Time Clock
Enter the Year:
•
•
The year displays.
The first programmable character, the
decade, blinks indicating the device is
ready to program the
decade digit of the year.
The LED under the # sign lights while setting the
year.
1. Use the UP and DOWN arrow buttons to move up and down through
the number 0-9 until the number
for the current decade is displayed
in the field.
32
The 2-digit date displays indicating the G3 is now
ready to program the date.
Enter the 2-digit Date:
The first programmable
character of the 2-digit
date blinks indicating the
device is ready to program the first digit of the
date.
The LED under the # sign lights while setting the date.
1. Use the UP and DOWN ARROW
buttons to move up and down
through the numbers 0-3 until the
first digit of the date is displayed in
the field.
332305L
Max Model Setup
2. Press the ENTER button to accept
the selection. The cursor automatically moves to the second digit of
the date.
5. The next number field to the right blinks and the
LED under the MM lights indicating the G3 is ready
to program the minutes fields.
6. Repeat steps 1-4 to set the minutes (MM) fields.
3. Use the UP and DOWN ARROW
buttons to move up and down
through the numbers 0-9 until the
second digit of the date is displayed in the field.
4. Press the ENTER button to set the
date.
7. After pressing the ENTER button to
set the time, the programmed Time
information is saved.
Programming ON Duration
•
OFF, C1 (C2, C3) or
P1 (P2, P3) displays,
identifying the function you are programming.
•
Selection of OFF, C1 (C2, C3) or P1 (P2, P3) designates the way pump run time is controlled:
The time displays indicating the G3 is now ready to
program the time.
Enter the Time:
•
The time displays in 24-Hour format. i.e., 2:45 PM
displays as 14:45.
•
The clock is set in Hours and Minutes (HH:MM).
•
The LED under the
HH lights when setting hours and the
LED under the MM
lights when setting
minutes.
C1, C2, C3 - Completing a specific number of
cycles measured by an external prox/cycle
switch
•
P1, P2, P3 - Reaching a specific pressure
threshold measured by an external pressure
switch - OR,
•
OFF - A specific duration of time elapses.
or
•
The first programmable number of the HH (hour)
filed blinks, indicating the device is ready to program
the first digit of the hour.
•
When programming a time of less then 12 hours,
you must program a leading zero in the first number
field and press the ENTER button to save the zero.
1. Use the UP and DOWN ARROW
buttons to move up and down
through the numbers 0-2 until the
desired number appears in the first
hour (HH) field.
2. Press the ENTER button to set the
number.
3. Use the UP and DOWN ARROW buttons to move
up and down through the numbers 0-9 until the
desired number for the second HH number field
appears.
4. Press the ENTER button to set the
number.
332305L
•
•
The LED next to C/P1 lights, indicating which sensor of the pump control
you are programming using either a
specific number of cycles or by monitoring a pressure switch.
•
C / P2 and C / P3 controls functions to the second
and third sensors (when sensors are used).
•
Only sensor inputs that are available on the unit can
be programmed.
NOTE: Field cannot be left blank. If C / P2 and C /
P3 are not used, OFF must be entered instead.
Cycle (C1, C2, C3) Setup
Cycle controls the number of lube cycles (as monitored
by an external cycle monitor) completed before the
pump rests.
NOTE:
•
You must program at least one cycle. Zero is not an
available option.
33
Max Model Setup
1. Use UP or DOWN arrow button to toggle display between
OFF / C1 / P1 on the display.
2. When C1 is
on display,
press the
ENTER
button to
save selection and begin programming Cycle data.
•
•
The first number
displayed after the
“C1” on the display blinks, indicating the device
is ready to program the number of C1 cycles.
The LED under the
# sign lights when
setting the number
of cycles.
3. Program the number of
cycles by pressing the UP or
DOWN ARROW button to
move up or down through
number 0-9.
4. The cycle field is a 2 digit number. When
the correct first numeral of the number
displays, press the ENTER button to
save the number. The cursor automatically moves to the second number field.
NOTE: A leading zero (0) must be entered in the
first field if the number of cycles is fewer than 10.
5. Press the ENTER button, to save the C1
information.
•
If your G3 is equipped with
more than one sensor input,
you will automatically be
prompted to begin selecting
the pump control type for the
next sensor. Repeat steps 1 - 5 to program cycles
for C2 and C3.
6. After you set the last field and press the
ENTER button, the G3 saves the Cycle
information and moves to setting
Backup Time, page 37.
Pressure Control (P1, P2, P3) Setup
•
For injector systems, monitoring pressure can be
used as a way to ensure sufficient pressure has
been reached to activate injectors. The pump runs,
building up enough pressure to cause injectors to
dispense fluid. Pressure continues to build to a preset maximum, activating the (user supplier) pressure switch. Then an external (user supplied) vent
valve opens and pressure reduces, priming the
injector for the next cycle.
•
Pressure control is an ON / OFF selection only.
1. Use the UP or DOWN arrow
button to toggle between OFF
/ C1/ P1.
2. When P1
displays,
press
ENTER
button to
save
selection.
3. If your G3 comes equipped with more than one sensor input, you will automatically be prompted to
begin selecting pump control type for the next sensor. Repeat steps 1 - 2 to program P2 and P3.
If P1 / P2 / P3 is selected the vent valve time is automatically set to 5 minutes. If the unit is used in an
injector based system and a sensor input is not
used, the user must update the vent valve time in
advanced programming. (See Advanced Programming, A-3 Vent Valve Time, page 51.)
Input Not Used
Select OFF if your system does not use the applicable
input.
1. Use UP or DOWN arrow button to toggle between OFF /
C1 / P1 on the display.
NOTE: If C / P2 and C / P3 are not used, the default
OFF setting must be entered instead.
34
332305L
Max Model Setup
Programming Backup Time
2. When
OFF is on
the display,
press the
ENTER
button to save selection.
If the sensor inputs are available and none are used in
the ON Mode, the definition of the entered time is ON
TIME.
Examples:
Model G3-G-24MX-2LFL00-1DMVA2R3 has 4 sensors,
so C/P1, C/P2, and C/P3 and Machine Count can all be
programmed.
Model G3-G-24MX-2LFL00-10CV00R0 has 1 sensor,
only C/P1 is available for programming.
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 completed 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 typical cycle and double that value (to a maximum of 30
minutes).
Backup Time is setup after Cycle or Pressure Sensor
Setup is complete.
NOTE: When programming a time of less than 10 minutes you must program the leading zero in the first number field and press the ENTER button to save the zero
selection.
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 to lock in the
selection. The next MM number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second MM number
field.
4. Press the ENTER button to lock in the
selection.
The next number field to the right
flashes and the LED lights under SS; indicating it is
ready to program the seconds fields.
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 programmed ON
Time information is saved.
The G3 automatically switches to the OFF Time
SETUP MODE.
NOTE:
•
The LED next to 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.
•
The first field (left side of display) blinks indicating
the device is ready for you to begin programming.
332305L
ON Time
•
The LED next to the clock in the ON
field lights, indicating you are setting
the ON Time parameters.
•
ON Time is set in Minutes and Seconds (MM: SS).
35
Max Model Setup
•
•
•
An LED flashes under
either MM when programming minutes
OR SS when programming seconds.
flashes and the LED lights under SS; indicating it is
ready to program the seconds fields.
OR
In SETUP MODE, the
number displayed in
the first field, on the
left side of display
blinks, indicating the
device is ready to program the ON Time minutes.
The total amount of ON Time cannot be 0 or exceed 30 minutes. If a
value of 0 or a value greater than
30 minutes is entered, the RED
alarm LED lights and the value must be
updated.
If this time does not meet the application needs,
contact Graco Customer Support.
Programming ON Time
NOTE: When programming a time of less than 10 minutes you must program a leading zero in the first number field and press the ENTER button to save the zero
selection.
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 to lock in the
selection. The next MM number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second MM number
field.
4. Press the ENTER button to lock in the
selection.
The next number field to the right
36
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 programmed ON
Time information is saved.
The G3 automatically switches to the OFF SETUP
MODE.
PUMP OFF / REST Setup
After setting the parameters for either Cycle (C1, C2 or
C3) or Pressure (P1, P2, or P3) ON modes, the OFF or
pump rest cycle must be set up. There are 3 ways to
control this function:
•
Machine Count switch activation, or
•
Machine Count activations limited by a maximum Time, or
•
A specific set amount of Time (similar to Time
Mode).
•
If the machine count sensor input is available
and not used in the OFF Mode, the definition of
the entered time is OFF TIME.
Machine Count
1. After you set the last ON Time field
and press the ENTER button, the G3
automatically switches to the
Machine Count setup if your model
has this feature.
Notice the LED next to 123 on the G3 display lights
indicating you are now in the Machine Count setup
mode.
2. Press the UP or DOWN
ARROW button to move up or
down through number 0-9.
3. When the correct number displays,
press the ENTER button to set the number.
NOTE: If the machine count input is available on the unit
and not used, the value MUST be set to zero (0).
4. Repeat 2 - 3 to set the remaining fields.
332305L
Max Model Setup
NOTE: After the Machine Count value is entered, the G3
can be programmed to backup the machine count input
with time.
•
Backup Time Setup
1. The OFF Time LED lights.
•
•
RUN: After
backup time
expires the pump
automatically
goes into an ON
cycle and shows
a machine count
warning.
FLT: After
backup time
expires, the
pump automatically goes into a
fault mode.
3. Press the ENTER button to set the
selection.
Backup Time
•
The LED next to the clock in the OFF
field lights, indicating you are setting
the Backup Time parameters.
•
OFF Time is set in Hours and Minutes
(HH: MM).
OR
•
In SETUP MODE the
number displayed in
the first field, on the
left side of display
blinks, indicating the
device is ready to program the Backup Time hours.
•
The total amount of Backup Time must
be at least twice as long as the programmed ON Time. If a value less
than twice the ON Time is entered, the
RED alarm LED lights and the value must be
updated.
OFF displays.
2. Press the UP or
DOWN ARROW button to change OFF to
RUN or FLT on the
display.
An LED flashes under
either HH when programming hours OR
MM when programming minutes.
If this time does not meet the application needs,
contact Graco Customer Support.
Programming Backup Time
NOTE: When programming a Backup Time of less than
10 hours you must program a leading zero in the first
number field and press the ENTER button to save the
zero selection.
1. To set the Backup Time use
the UP or DOWN ARROW
button to scroll through
numerals 0 to 9 until the
desired number appears in
the first HH (hour) field.
2. Press the ENTER button to lock in the
selection. The next HH number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second HH number
field.
4. Press the ENTER button to lock in the
selection.
The next number field to the right
flashes and the LED lights under MM; indicating it is
ready to program the minutes fields.
332305L
37
Max Model Setup
5. Repeat steps 1 - 4 to set the next MM (minutes)
fields.
6. After pressing the ENTER button to set
the last MM field, the OFF Time information is saved.
7. After selecting ON, refer to page 34.
NOTE: Backup time can be set in HH:MM for the
machine count input.
OFF Time
•
The LED next to the clock in the OFF
field lights, indicating you are setting
the OFF Time parameters.
•
OFF Time is set in Hours and Minutes
(HH: MM).
•
•
•
An LED flashes under
either HH when programming hours OR
MM when programming minutes.
OR
In SETUP MODE the
number displayed in
the first field, on the
left side of display
blinks, indicating the
device is ready to program the OFF Time hours.
The total amount of OFF Time must be
at least twice as long as the programmed ON Time. If a value less
than twice the ON Time is entered, the
RED alarm LED lights and the value must be
updated.
1. To set the OFF Time use the
UP or DOWN ARROW button
to scroll through numerals 0
to 9 until the desired number
appears in the first HH (hour)
field.
2. Press the ENTER button to lock in the
selection. The next HH number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second HH number
field.
4. Press the ENTER button to lock in the
selection.
The next number field to the right
flashes and the LED lights under MM; indicating it is
ready to program the minutes fields.
5. Repeat steps 1 - 4 to set the next MM (minutes)
fields.
6. After pressing the ENTER button to set
the last MM field, the OFF Time information is saved.
Prelube
The Prelube function determines operation of the pump
when power is applied. It can be set to OFF or ON.
OFF (default) - The unit resumes its lubrication cycle at
the point it was at when power was removed.
ON - The unit begins a pump cycle.
If this time does not meet the application needs,
contact Graco Customer Support.
Programming OFF Time
NOTE: When programming a time of less than 10
hours you must program a leading zero in the first number field and press the ENTER button to save the zero
selection.
38
Setting Prelube
1. After you set the OFF Time information and press
the ENTER button, the G3 automatically switches to
the Prelube Delay setup.
Notice the LED next to the prelube
icon on the G3 display lights indicating you are now in the Prelube setup
mode.
332305L
Max Model Setup
2. OFF displays. If you
want the prelube
cycle to begin immediately, leave this set
to OFF.
3. Press the ENTER button to set the
selection.
4. If you want to set a
prelube delay time,
press the DOWN
ARROW button to
change OFF to ON
on the display.
Prelube Delay
Prelube Delay can be entered to delay the start of the
pump’s cycle on power up. If prelube is set to ON, a prelube delay time in MM:SS must be entered. By default,
the delay is set to 0 (begin an ON cycle immediately).
Delaying the prelube function may be desired if other
critical functions or systems of your machine or vehicle
are also coming on line during power up.
1. Prelube Delay is set in
MM:SS (minutes and seconds). To set the 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.
The maximum length of time Prelube Delay can be
set to is 59:59 (59 minutes:59 seconds).
2. Press the ENTER button to lock in the
selection. The next MM number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second MM number
field.
4. Press the ENTER button to lock in the
selection.
flashes and the LED lights under SS; indicating it is
ready to program the seconds fields.
5. Repeat steps 1 - 4 to set the SS (seconds) fields.
6. After pressing the ENTER button to set
the last SS field the G3 automatically
switches to the RUN MODE.
DMS™ Models Only
Downloading Data
1. Plug the USB flash drive into the USB port.
NOTE: The G3 pump stops pumping as soon as the
USB flash drive is plugged into it.
2. The system automatically begins downloading data
to the USB drive.
3. “data” is displayed while the system
is downloading files.
4. When download is finished, “done” is
displayed.
5. G3 pump resumes operation.
6. Remove the USB flash drive.
Storing Pump Program Settings
to the Flash Drive
The pump program settings file is named either:
GRACO/G3Config/g3config.bin (for 0209 and earlier
versions) or GRACO/Config/config.bin (for 0706 and
later versions): This file cannot be modified. Modification
of the file or file name (by anyone but the issuer) may
cause it to be unusable.
1. Plug the USB flash drive into the USB port.
NOTE: The G3 pump stops pumping as soon as the
USB flash drive is plugged into it.
2. The system automatically begins downloading data
to the USB drive.
3. “data” is displayed while the system
is downloading files.
The next number field to the right
332305L
39
Max Model Setup
4. When download is finished, “done” is
displayed.
5. G3 pump resumes operation.
6. After the download is complete, press and hold the UP
and DOWN ARROW button
for 3 seconds to store the current setup to the USB flash
drive.
6. After the download is complete, press and hold the
RESET button and UP
ARROW button for 3 seconds
to upload the setup stored in the USB flash drive.
7. “data” is displayed while the unit is
uploading the configuration data.
8. When upload is finished, “done” is
displayed.
7. “data” is displayed while the unit is
downloading and storing the configuration on the USB drive.
9. G3 pump resumes operation.
8. When configuration is stored, “done”
is displayed.
11. After the USB flash drive is
removed, press and hold the
UP and DOWN ARROW buttons for 3 seconds to enter
the SETUP MODE (see
Entering Setup Mode, page 31).
9. G3 pump resumes operation.
10. Remove the USB flash drive.
Uploading Pump Program
Settings to the Pump
1. Plug the USB flash drive into the USB port.
NOTE:
•
•
10. Remove the USB flash drive.
12. In SETUP MODE, set the YEAR, MONTH, DATE
and TIME (see Setting the Real Time Clock, page
32).
13. After pressing the ENTER button to set
the TIME, press the RESET button to
exit the SETUP MODE.
The USB flash drive must contain file
GRACO/G3Config/g3config.bin (for 0209 and
earlier) or GRACO/Config/config.bin (for 0706
or later).
Viewing the UNIT DMS ID Number
NOTE: 0707 pumps can take either file setting
to upload, but earlier pumps cannot. File names
and folders may need to be changed manually
when importing settings to an earlier version
pump from a later version.
2. The Unit DMS ID number displays. The
unit continues to normal operation while
the DMS ID is displayed.
The G3 pump stops pumping as soon as the
USB flash drive is plugged into it.
1. In RUN mode, press and hold the
DOWN ARROW button.
3. Release the DOWN ARROW button after viewing
the DMS ID number.
2. The system automatically begins downloading data
to the USB drive.
3. “data” is displayed while the system
is downloading files.
4. When download is finished, “done” is
displayed.
5. G3 pump resumes operation.
40
332305L
Operation / Data Log
Operation / Data Log
During operation the G3 Pump stores information as
Log and Summary Files.
Logs contain the following information:
•
Log Name
•
DMS ID Number
•
Current Software Graco Part Number
•
Current Software Version
•
Date and Time of Upload
System Event Log
The System Event Log lists the date and time of the last
800 common system events such as pump cycles, manual run and setting changes. The most recent event is
listed first.
Sample System Event Log
Example Event Log 1: Pump cycle of a divider valve
system with a proximity switch set to detect 5 divider
valve cycles.
G3 System Event Log
DMS ID Number: 0025 (see page 40)
Software Part Number: 16F821
Software Version: 1019
09/29/2010 14:1400
Date
9/29/2010
9/29/2010
9/29/2010
9/29/2010
9/29/2010
9/29/2010
9/29/2010
Time
14:13:02
14:13:02
14:12:39
14:12:34
14:12:28
14:12:23
14:12:17
Description
Pump Run Off
C1 Cycle Completed
C1 Cycle Detected
C1 Cycle Detected
C1 Cycle Detected
C1 Cycle Detected
Pump Run On
The log file is stored in a folder structure created by the
pump DMS ID and download date. If multiple downloads
are done on the same date, the existing files will be written over.
The folder structure is as follows:
GRACO/{DMS_id}/{download date - YYYYmmDD}/EVENTLOG.CSV
Example: GRACO/00025/20100911/EVENTLOG.CSV.
332305L
41
Operation / Data Log
Example Event Log 2: Pump cycle of an injector valve
system with a pressure switch feedback.
Date
9/29/2010
9/29/2010
9/29/2010
9/29/2010
9/29/2010
Time
13:28:12
13:23:12
13:23:11
13:23:11
13:22:20
Description
Venting Completed
Venting Detected
Pump Run Off
P1 Pressure Completed
Pump Run On
Common System Events are listed below.
Pump Run On
The pump entered an on cycle and is
operating and dispensing material.
Pump Run Off
The pump entered an off cycle and is
not dispensing.
Pump Run Canceled
A pump on cycle was canceled by
pressing the cancel button on the front
panel and holding it for 3 seconds.
Power On
The pump powered on.
Power Off
The pump powered off.
Program Variable
Change
The setup mode was entered.
C1 Cycle Detected
The system is set up to monitor a proximity switch on a divider valve using the
sensor input (C1, C2, and/or C3) and
has detected one divider valve cycle.
C2 Cycle Detected
C3 Cycle Detected
C1 Cycle Completed
C2 Cycle Completed
C3 Cycle Completed
P1 Pressure Completed
P2 Pressure Completed
P3 Pressure Completed
The system is set up to monitor a proximity switch on a divider valve using the
sensor input (C1, C2, and/or C3) and
has achieved the number of counts
required by the system for that input,
completing a pump on cycle.
The system is set up to monitor a pressure switch for an injector system using
sensor input (P1, P2, and/or P3), the
system has achieved pressure and the
switch has activated, completing a
pump on cycle.
Machine Count
Completed
The system is set up to monitor a sensor on the equipment being lubricated
using the machine count input and has
achieved the number of counts required
by the system for that input, completing
a pump off cycle and initiating a pump
on cycle.
Local Manual Run
Initiated
The manual run button was pressed, initiating a pump on cycle.
Remote Manual
Run Initiated
The remote manual run button was
pressed initiating a pump on cycle.
42
Venting Detected
In an injector system, the pump on cycle
has completed and the system is currently venting pressure through the vent
valve.
Venting Completed
in an injector system, the system completed the vent time.
Prelube Initiated
The pump has entered a prelube delay
after powering up.
Prelube Delay Com- The pump has completed prelube delay
pleted
and will begin a pump on cycle.
Successful Pin
Code Entry
The pin code was successfully entered
and the user has entered setup mode.
Firmware Update
Completed
The firmware was updated.
Low Power Fault
Pump On
The power source does not have
enough power to power the pump when
it turns on. Replace power source
Low Power Warning Cleared
The voltage of the power source
dropped below an acceptable threshold.
The warning was cleared either by user
intervention, or by self-correction.
Low Power Fault
Cleared
The voltage of the power source
dropped below and acceptable threshold for longer than 15 minutes and the
pump failed out. The fault was cleared
by the user.
Error Log
The Error Log lists Set Time and Clear Time for the last
400 faults and warnings. The most recent event is listed
first.
The log file is stored as:
GRACO/{DMS_id}/{download date - YYYYmmDD}/ERRORLOG.CSV
Example: GRACO/00025/20100911/ERRORLOG.CSV.
332305L
Operation / Data Log
Sample Error Log
G3 Error Log
DMS ID Number: 00025 (see page 40)
Software Part Number:16F821
Software Version:0205
12/31/2015 23:04:00
Date
12/31/2015
12/31/2015
12/31/2015
12/31/2015
12/31/2015
12/31/2015
12/31/2015
12/31/2015
12/31/2015
Time
23:03:54
23:03:42
23:03:32
23:03:22
23:03:22
23:03:19
23:03:19
23:02:20
23:02:11
Description
Low Level Cleared
Low Level Fault
Low Level Warning
P2 Not Detected Cleared
C1 Not Detected Cleared
P2 Not Detected
C1 Not Detected
Machine Count Not Detected
Machine Count Not Detected
Common Error Log entries are listed below.
Software Fault
An internal software error
occurred. Contact Graco Customer Service.
Low Level Warning
The unit entered a low level
warning mode and is running
low on material. The pump
continues to dispense material
for the duration of the low level
alarm time specified by the
unit.
Low Level Fault
The alarm time in low level
warning has elapsed. The unit
will not pump until the reservoir
is filled and the fault is cleared.
C1 Not Detected
In a divider valve system, the
system has not received the
programmed number of divider
valve cycles for the specified
input in the programmed
backup time.
C2 Not Detected
C3 Not Detected
P1 Not Detected
P2 Not Detected
P3 Not Detected
332305L
In an injector system the system has not received a signal
from the pressure switch in the
designated backup time.
System Already Pressurized 1
System Already Pressurized 2
System Already Pressurized 3
In an injector system the pressure switch is activated when
the unit enters a pump on
mode and may not have vented
properly.
Machine Count Sensor The specified number of
Failure
machine count input activations was not received within
the designated backup time.
Motor Overcurrent
The unit is out of expected
motor current range. Check the
system to determine that it is
functioning correctly (i.e., no
blocked lines). Continued operation at excessive motor currents will cause degradation in
pump life.
High Temperature
Warning
Internal temperature of the unit
is above the designated operating. Check the unit and system to determine that it is
functioning correctly. Operating outside of the specified
temperature range may cause
reduced performance and possible unit failure.
Low Temperature
Warning
Internal temperature of the unit
is below the designated operating. Check the unit and system
to determine that it is functioning correctly. Operating outside
of the specified temperature
may cause reduced performance and possible unit failure.
USB Unable to Mount
The USB flash drive that was
installed was unable to connect
and communicate with the
pump.
USB Unsupported
Device
The USB flash drive is unsupported. Use a different flash
drive.
USB File Not Found
The pump program setting file
was not found or created correctly. Restore the setting file to
the flash drive.
43
Operation / Data Log
USB Folder Navigation The pump program setting file
was not found or created correctly. Restore the setting file to
the flash drive.
USB Invalid File
The pump program settings file
was not found or created correctly. Restore the setting file to
the flash drive.
Failed Pin Code Entry
A failed attempt was made to
enter the pin code password.
44
332305L
Operation / Data Log
Functional Summary
The Functional Summary contains two types of data.
•
The first report type, labeled User under the Type
heading in the first column of the Sample Functional
Summary, only provides data compiled since the
last time the Functional Summary was reset through
present day (see A6 - Clearing the Functional and
Technical User Summary, page 53).
•
The second report type, labeled Factory under the
Type heading in the first column of the Sample
Functional Summary, covers the cumulative life of
the pump from the first day it was put into service
through present day.
This is very similar to an odometer in your car.
The log file is stored as:
This is very similar to the resettable trip odometer in
your car.
GRACO/{DMS_id}/{download date - YYYYmmDD}/FUNCSUM.CSV
Example: GRACO/00025/20100911/FUNCSUM.CSV
Sample Functional Summary
(see page 40)
332305L
45
Operation / Data Log
Common Functional Summary Data entries are listed
below.
Number of Cycles
The number of lubrication cycles
the unit has started.
Total Run Hours
Total amount of hours the pump
has been in the ON mode of the
ON/OFF cycle.
Total Powered On Hours
Total number of hours that the
unit has been powered on.
Local Manual Run
The number of times the manual
run button was pressed.
Remote Manual Run
The number of times the remote
manual run button was pressed.
Average Run Time
The average amount of time per
lubrication cycle that the pump
has been running (MM:SS).
Average Cycle 1 Time
The average amount of time the
unit has been operating before
the specified feedback for the
sensor input was received (proximity switch counts in divider
valve systems and pressure
switch activation in injector systems).
Average Cycle 2 Time
Average Cycle 3 Time
Average Duty Cycle
The average percentage of time
the unit has been pumping while
it has been powered on.
Max Duty Cycle
The highest percentage of time
for one lubrication cycle that the
unit has been pumping while it
has been powered on.
Total Low Level Faults
Total number of low level faults.
Total Cycle Pressure
Faults
Total number of faults related to
sensor feedback in an injector or
divider valve system.
Total Other Faults
Faults other than low level or
sensor feedback.
Total Fault Hours
Number of hours the system has
been powered on in fault mode.
Total Low Level Warnings
Number of low level warning
conditions.
Total Cycle Pressure
Warnings
Total number of warning conditions related to sensor feedback.
This is only applicable if fault
retries are used.
Total Other Warnings
All other warnings including temperature and motor current.
46
332305L
Operation / Data Log
Technical Summary
GRACO/{DMS_id}/{download date - YYYYmmDD}/TECHSUM.CSV
The Technical Summary contains two types of data.
Example: GRACO/00025/20100911/TECHSUM.CSV
•
The first report only provides data compiled since
the Pump Summary was reset to present day (see
A6 - Clearing the Functional and Technical User
Summary).
This is very similar to the resettable trip odometer in
your car.
•
Common Technical Summary Data entries are listed
below.
Average Input Board
Voltage (DC)
The average input voltage measured by the internal circuit board.
Peak Input Board Voltage The peak input voltage measured
(DC)
by the internal circuit board.
The second is a report that covers the cumulative
life of the pump from the first day it was put into service to present day.
Average Motor Current
The average motor current measured by the unit.
Peak Motor Current
The peak motor current measured by the unit.
This is very similar to an odometer in your car.
Average Internal Temperature
The average internal temperature
seen by the unit.
Peak Internal Temperature
The peak internal temperature
seen by the unit.
The log file is stored as:
Sample Technical Summary
G3 Technical Summary
DMS ID Number: 00025 (see page 40)
Software Part Number:16F821
Software Version: 0205
12/27/201 9:50:51
0
Latest Values
Temp
Voltage
31C
23.877
Type
User
Factory
332305L
Start Date Average
Board
Voltage
12/21/201 23.877
0
9/30/2010 22.804
Peak
Board
Voltage
23.877
Average
Motor
Current
0.062
Peak
Motor
Current
0.062
Average
Internal
Temp
30C
Peak
Internal
Temp
35C
Low
Internal
Temp
28C
23.877
1.091
0.362
33C
42C
-10C
47
Advanced Programming
Advanced Programming
There are 11 Advanced Programming options. The following Table Identifies each option and when it is used.
Advanced
Option
Model
A1
Max
A2
Max
A3
Max
A4
A5
Max
Max
Setting
Lockout
Code (Optional)
Low Level Alarm
Time
Vent Valve Time
Alarm Retry
Active Alarm
Format/ Description
Why Use This?
Secures setup modes with PIN
Prevents unauthorized users to adjusting settings.
To accommodate most lubrication situations, a
conservative amount of time is programmed
between the low level warning and fault to help
protect unit from running dry. If necessary the
amount of time the unit runs before stopping due
to a low level fault can be adjusted.
MM:SS (minutes:seconds) sets
amount of time between Low
Level Warning to Low Level
Fault.
Default = 3 minutes
MM:SS (minutes:seconds) sets
amount of time vent valve stays
open after Pump ON Mode.
Default = 5 minutes
Sets number of automatic
retries after a Cycle or Pressure
Alarm.
Default = 0
Changes alarm output behavior.
Default = OFF
• In an injector based system that does not use
a sensor for feedback, determines the amount
of time the system vents.
• Vent time can be modified.
Establishes the number of times the unit automatically retries lubricating after a cycle or pressure alarm to determine if a temporary or false
signal can be cleared.
Uses alarm output to determine if a unit has an
alarm AND/OR loses power.
The output turns ON when power is applied. It
turns OFF when power is lost or an alarm
occurs.
Normal operation (OFF) will only activate alarm
output in an alarm condition when power is on.
Can change (set to ON) to activate alarm with
power ON and deactivate with power OFF OR
warning.
A6
A7
™
DMS
Equipped
Models
Max
Functional and
Technical User
Summary Reset
Constant Alarm
Output on Fault
Used to manage power outage.
Clears the Functional and Tech- Allows user to track lube events from a specific
nical User Summaries
point (reset), i.e. a month to month evaluation.
Changes alarm output behavior.
This function changes the behavior of the alarm
output in a fault from either toggling once every
second or steady on.
Default = OFF
Firmware 6.02 and later
A8
Max
4 Digit Hour Off
Time
Changes maximum OFF time.
Default = OFF
A9
Max
and
“08” option
Toggle Low Level
Output on Warning
or Fault
Changes Low Level Indication
behavior.
This function changes OFF time from HH:MM to
HHHH. It allows a maximum of 9999 hours of
OFF time.
This function changes the behavior of the low
level output in a warning or fault from either
steady on or toggling once per second.
Default = OFF
48
332305L
Advanced Programming
Firmware 6.04 and later for non-DMS models and 07.07 and later for DMS models.
A10
Max
Low Level Reset
Upon Power ON
Changes low level fault upon
power ON.
This function changes the behavior of the low
level fault upon power ON.
A11
Max
Warning OFF
through alarm relay
Default = OFF
Changes alarm output behavior.
This function changes the behavior of the alarm
output in a warning condition to always OFF.
Default = OFF
Firmware 6.06 and later for non-DMS models and 07.09 and later for DMS models.
A12
Max
Prelube Sequences Changes the number of the
Prelube sequences.
A13
Max
MM:SS Off Time
Default = 0001
Changes the OFF time programming from HH:MM to
MM:SS
This function changes the behavior of the prelube function to add more lubrication sequences
upon pump start up.
This function changes the programming of the
OFF time.
Default = OFF
Entering a PIN Code for the First Time
A1 - Setting Up PIN Code
A PIN Code can be programmed into the G3 to protect
the settings from inadvertently being changed by unauthorized users.
1. Press the UP ARROW button for 10
seconds.
The LED next to the LOCK ICON on the display lights, indicating you have entered the
PIN Mode.
2. The word OFF appears in the
display. Press the UP or
DOWN ARROW button to
change this to ON.
3. Press the ENTER button to enter the
PIN Code.
4. The cursor automatically is
positioned to entered the first
character of the PIN Code.
Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.
332305L
5. Press the ENTER button to set the number. The cursor automatically moves to
the next number field.
6. Repeat steps 4 and 5 for each PIN Code prompt
field.
7. Press the ENTER button to save the
PIN Code and exit Advanced Setup.
Entering Advanced Setup
Press the UP ARROW button for 10 seconds.
If the G3 was previously set up to require a
PIN Code, the LED next to the LOCK ICON lights, indicating a PIN Code is required.
1. The cursor is automatically
positioned to enter the first
character of the PIN Code.
Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.
2. Press the ENTER button to set the number. The cursor automatically moves to
the next number field.
49
Advanced Programming
3. Repeat steps 1 and 2 for each PIN Code prompt
field.
If the PIN Code you entered is correct, the first editable
character on the display will flash.
Selecting Advanced Setup Options
1. Press the UP or DOWN
ARROW button to move up or
down through Advanced
Options A1 - A13.
2. Press the ENTER button to set the
selection.
50
332305L
Advanced Programming
A2 - Low Level Alarm Time
Pump ON mode only.
Programs the amount of time in MM: SS (minutes and
seconds) the pump can run between a Low Level Warning and a Low Level Fault to help protect unit from running dry.
The maximum recommended length of time is 3:00 minutes.
Fault, and Low Level LED illuminate. (Max Model Display shown in illustration below).
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second MM number
field.
4. Press the ENTER button to lock in the
selection.
The next number field to the right
flashes and the LED lights under SS; indicating it is
ready to program the seconds fields.
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 programmed ON
Time information is saved.
Unit exits Advanced Programming.
A3 - Vent Valve Time
The Vent Valve Time is the amount of time the vent
valve stays open after a cycle is completed.
The recommended Vent Valve Time is 5 minutes.
To bypass the Vent Valve Time enter a value of 00:00.
FIG. 35
Vent Valve time must be less than the programmed OFF
time (page 38). If it is not set to a value less than the
programmed OFF time, the G3 will automatically adjust
the time to a value 2 seconds less than the set OFF
time.
NOTE: When programming a time of less than 10 minutes you must program a leading zero in the first number field and press the ENTER button to save the zero
selection.
1. To set the time use the UP or
DOWN ARROW button to
scroll through numerals 0 to 9
until the desired number
appears in the first MM (minutes) field.
2. Press the ENTER button to lock in the
selection. The next MM number field to
the right flashes indicating it is ready for
programming.
332305L
51
Advanced Programming
To set Vent Valve Time:
NOTE:
•
The LED next to the clock in the OFF
field lights and P1, P2, and P3, indicating the Vent Valve Time is being
programmed.
7. After pressing the ENTER button to set
the last seconds field, all the programmed Time information is saved.
Unit exits Advanced Programming.
A4 - Alarm Retry
•
Time is set as minutes and seconds (MM:SS) only.
•
The small flashing
LED under the MM
indicates you are
setting Minutes.
•
The first field (left
side of display) blinks
indicating the device
is ready for you to
begin programming.
•
When programming a time of less then 10 minutes
you must program a leading zero in the first number
field and press the ENTER button to save the zero
selection.
Programs the number of times G3 will automatically
retry running a lubrication cycle after a cycle or pressure
alarm activates. The default setting is 0. For assistance
determining a reasonable number of Alarm Retries to
program for your application, contact Graco Customer
Service or your local Graco distributor.
1, 2, and 3 and Fault LED’s illuminate.
1. To set the Time use the UP or DOWN ARROW button to scroll through numerals 0 to 5 until the
desired number appears in the first minute field.
2. Press the ENTER button to lock in the
selection. The next minute field to the
right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second minute field.
4. Press the ENTER button to lock in the
selection.
5. The next number field
to the right flashes
and the LED lights
under SS; indicating
it is ready to program
the Seconds fields.
FIG. 36
To set the Alarm Retry:
1. The default value
0000 appears in the
display.
2. Press the UP or DOWN
ARROW button to move up or
down through number 0-9.
6. Repeat steps 1 - 4 to set the MM (seconds) fields.
52
332305L
Advanced Programming
3. When the correct number displays,
press the ENTER button to set the number.
4. Repeat 2 - 3 to set the remaining fields.
5. Press the ENTER button to exit
Advanced Programming.
3. Press the ENTER button to exit
Advanced Programming.
A6 - Clearing the Functional and Technical
User Summary (DMS™ Models only)
The Pump Summary shows run details since the last
time the summary was cleared.
A5 - Active Alarm
Changes the alarm output behavior. Uses output to
determine if a fault has occurred.
Fault and ON LED’s illuminate.
FIG. 38
FIG. 37
1. The default OFF displays.
1. Press the UP or DOWN
ARROW button to move
through Advanced Options
until Advanced Option A6 is
displayed.
2. Press the ENTER button.
3. “Data” displays.
2. Press the UP or DOWN
ARROW button to change
OFF to ON on the display to
activate alarm condition.
4. Press the RESET button. “Reset” displays.
The summary data is
cleared.
5. Press the RESET or
ENTER button to exit.
332305L
53
Advanced Programming
A7- Constant Alarm Output ON Fault
A8 - 4 Digit Hour OFF Time
This function changes the behavior of the alarm output
in a fault from either toggling once every second
(default) or steady on.
Changes the OFF time from HH:MM to HHHH. Allows
for a maximum of 9999 hours of OFF time.
OFF LED illuminates.
Fault and Warning LEDs Illuminate
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
FIG. 40
FIG. 39
1. The default OFF is
displayed. The alarm
output will toggle
once a second.
2. Press the UP or DOWN
ARROW to change OFF to
ON on the display to change
the alarm output to be on
steady
1. The default OFF displays.
2. Press the UP or DOWN
ARROW button to change
OFF to ON on the display to
activate alarm condition.
3. Press the ENTER button to exit
Advanced Programming.
3. Press the ENTER button to exit
Advanced Programming.
54
332305L
Advanced Programming
A9 - Toggle Low Level Output on Low Level
Warning or Fault
This function changes the behavior of the low level output in a warning or fault from either steady on (default)
or toggling once every second.
Models with Firmware 6.03 and
later. DMS Models with Firmware
7.07 and later.
A10 - Low Level Reset Upon Power On.
Low Level and Warning LEDs Illuminate
This function changes the behavior of the low level upon
pump power on. When A10 is on, a low level fault clears
when the pump power is cycled. The pump will revolve 5
revolutions, checking to see if the low level condition is
still present. If not, it will self clear and continue. If a low
level condition exists during the 5 revolutions, it will go
into a low level fault.
Low Level ON LED illuminates (FIG. 42).
FIG. 41
1. The default OFF is
displayed. The alarm
output will toggle
once a second.
FIG. 42
2. Press the UP or DOWN
ARROW to change OFF to
ON on the display to change
the alarm output to be on
steady.
1. The default OFF is displayed. The
alarm output will toggle once a
second.
3. Press the ENTER button to exit
Advanced Programming.
2. Press the UP or DOWN
ARROW button to change
OFF to ON on the display to
change the low level reset
upon power on.
332305L
55
Advanced Programming
3. Press the ENTER button.
A11- Warning Off Through Alarm Relay
This function changes the behavior of the alarm output
in a warning condition to always off.
Models with Firmware 6.06 and
later for non-DMS models.
Models with Firmware 7.09 and
later for DMS models
A12 - Prelube Sequences
Fault and Warning LEDs Illuminate
This function changes the behavior of the prelube function to add more lubrication sequences upon pump start
up. While running multiple sequences, after the initial
sequence, PL:xx will be displayed showing how many
sequences are left.
Note: if pump has option “08” and using a pressure
switch with multiple sequences, a vent delay time must
be programmed under Advanced Programming Option
A3.
Prelube LED illuminates (FIG. 42)
FIG. 43
1. The default OFF is
displayed. The alarm
output will turn on
during a warning
condition.
2. Press the UP or DOWN
ARROW to change OFF to
ON on the display to change
the alarm output to be off
during a warning condition.
3. Press the ENTER button to exit
Advanced Programming.
56
FIG. 44
1. The default 0001 is displayed.
When Prelube is on, it will run
one sequence.
2. Press the UP or DOWN
ARROW button until desired
number of prelube
sequences displays.
332305L
Advanced Programming
NOTE: When prelube is on, and the pump is powered-up, the pump will run this amount of lubrication
ON sequences.
3. Press the ENTER button to exit
Advanced Programming after the last
digit of the prelube sequence is displayed.
2. Press the UP or DOWN
ARROW to change OFF to
ON on the display. The
OFF/Backup Time in setup
mode will be displayed in
MM:SS (Minutes/Seconds).
3. Press the ENTER button to exit
Advanced Programming.
A13- MM:SS OFF Time
This function changes the programming of the OFF
Time.
OFF and Warning LEDs Illuminate
FIG. 45
1. The default OFF is
displayed.
OFF/Backup time in
setup mode is displayed in HH:MM
(Hours/Minutes).
332305L
57
Run Mode
Run Mode
HH
MM
SS
##
Time Control
!
After setup is complete, the G3 automatically begins to
run the OFF Time sequence (FIG. 46).
•
The G3 runs the programmed OFF sequence.
(Notice the OFF Time LED on the display lights and
the OFF Time counts down on the display.)
•
MM
SS
##
OFF
MM : SS
HH : MM
C
P1
The example shown in FIG. 46 shows an OFF Time
of 1 hour and 32 minutes before the lubrication cycle
begins.
HH
ON
C
P2
C
C
P3
P
123
!
FIG. 47
ON
OFF
MM : SS
HH : MM
•
C
P1
C
P2
C
C
P3
P
•
When the OFF Time count reaches zero, the G3
Automatic Lubrication Pump turns the pump on and
it runs for the programmed ON Time cycle (FIG. 47).
(Notice the ON Time LED is now illuminated on the
display.)
•
This sequence repeats itself until the device is
reprogrammed or an alarm occurs.
123
FIG. 46
The example shown in FIG. 47 shows an ON Time of
8 minutes and 42 seconds before the lubrication
cycle ends.
When the ON Time count reaches zero, the pump
shuts off again and the system again runs OFF
Time cycle and the OFF Time LED is now again illuminated (FIG. 46).
•
If power to the pump is lost during a lubrication
cycle, when power is restored the pump will resume
the cycle with the same amount of time remaining in
the cycle as when the power was lost.
Lubrication Mode (Pump ON) Controls
In Max models the Lubrication Mode (Pump ON) can be
controlled by either cycle and/or pressure sensors.
If cycle and/or pressure controls have been set to something other than OFF the display will alternate between
cycles (C1, C2, C3) and/or active sensors (P1, P2, P3)
and Backup Time.
If cycle or pressure controls have been set to OFF then
the Lubrication Mode (Pump ON) will be controlled by
On Time (see Time Control, page 58).
With cycle and/or pressure controls set, the lubrication
cycle (Pump ON) is ended by meeting all required cycle
and/or pressure settings.
58
332305L
Run Mode
Cycle Control
Pressure Control
•
A set number of triggered counts in a cycle
based system (C1). Typically a proximity switch
connected to a divider valve.
•
A single triggered count in a pressure based
system (P1). Typically a pressure switch on the
end of a line of injectors.
•
The LED next to the appropriate sensor (C/P1,
C/P2, C/P3) illuminates.
•
The LED next to the appropriate sensor (C/P1,
C/P2, C/P3) illuminates (FIG. 49 and FIG. 50).
•
The display indicates the sensor (C1, C2, C3)
and the remaining cycles for that sensor (FIG.
48).
•
The display indicates the sensor (P1, P2, P3)
and whether the pressure switch for that sensor
has been triggered or not.
- 01 = pressure switch has not been triggered
- 00 = pressure switch is triggered.
The example shown in FIG. 48 shows sensor C1
with 5 cycles remaining.
HH
MM
SS
##
The example shown in FIG. 49 shows sensor P1
with a pressure switch that has been triggered.
!
FIG. 50 (page 60) shows sensor P2 with a pressure switch that has NOT been triggered.
ON
OFF
MM : SS
HH : MM
HH
MM
SS
##
!
C
P1
C
P2
C
C
P3
P
123
ON
OFF
MM : SS
HH : MM
C
P1
FIG. 48
C
P2
C
C
P3
P
123
FIG. 49
332305L
59
Run Mode
Backup Time
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
•
In both Cycle and Pressure modes a Backup
Time (maximum run time) has been set.
•
The LED(s) next to all programmed sensors
(C/P1, C/P2, C/P3) illuminate.
•
The display shows time remaining until a fault.
The example shown in FIG. 51 shows 14 minutes and 33 seconds left until the fault occurs.
•
C
P1
C
P2
C
C
P3
P
If all cycle and/or pressure requirements are
met the unit exits the lubrication cycle (Pump
ON) and enter the rest cycle (Pump OFF).
123
HH
FIG. 50
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
FIG. 51
Rest Mode (Pump OFF) Controls
In Max models the Rest Mode (Pump OFF) is controlled
by machine counts.
If the Machine Count is set to a value greater than 0000
and the Backup Time option is activated, the display
will alternate between Machine Counts and Backup
Time.
If Machine Count has been set to a value greater than
0000 and the Backup Time option is NOT activated, the
display will only show the number of Machines Counts
remaining.
60
332305L
Run Mode
With machine count set, the Rest Cycle (Pump OFF) is
ended when the machine count reaches zero (0000).
Machine Count
Backup Time
In Machine Count mode, if a Backup Time (maximum
rest time) has been set:
•
A set number of triggered counts.
•
The LED next to 1-2-3 illuminates (FIG. 53).
•
The LED next to 1-2-3 illuminates (FIG. 52).
•
•
The display indicates the number of machine
counts remaining.
The display alternates between machine counts
remaining and backup time.
The example shown in FIG. 53 shows 4 hours
and 17 minutes remaining until a fault or lubrication mode (pump ON) occurs.
The example shown in FIG. 52 shows the
remaining number of machine counts is 0045.
•
HH
MM
SS
##
!
If the Machine Count requirements are met the
unit will exit the Rest Mode (Pump OFF) and
enter the Lubrication Mode (Pump ON).
HH
ON
OFF
MM : SS
HH : MM
C
P1
C
P2
C
C
P3
P
123
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
FIG. 52
FIG. 53
OFF Time
In Max models if the Machine Count is set to 0000 then
Reset Mode (Pump OFF) is controlled with OFF Time
(see Time Control, page 58).
332305L
•
The LED next to the clock in the OFF field illuminates.
•
The display shows the time remaining until the lubrication cycle begins.
61
Run Mode
Additional Controls
•
Venting
In Max models a Vent Time can be set using the
Advanced Programming mode (page 51). This is typically done in a Pressure Based System (P1) to allow
injectors to reset.
•
Unit vents for a set amount of time (not displayed).
•
The LED’s next to C/P1, C/P2, C/P3 flash while
unit is venting.
•
The pump will not run while in Venting mode.
•
If Machine Count is set, the display will alternate
between machine counts remaining and backup
While unit is venting, VEnt will display and alternate with Machine Count and the Backup Time
or the OFF Time.
HH
MM
SS
##
Max Model - display shows Cycle/Pressure/Backup Time (See Max Model Lubrication
Mode Controls, page 58).
Prelube Delay
The Prelube function has been selected. Prelube delay
is set to something other than 00:00:
•
Power to the unit cycles OFF then ON.
•
Unit immediately begins the Prelube Delay
count down and after the Prelube Delay time
runs out, the lubrication cycle begins.
•
The LED next to the clock in the OFF field is illuminated (FIG. 55).
•
The Prelube LED lights (FIG. 55).
•
The display shows time remaining until lubrication cycle begins. The example shown in FIG. 55
shows 8 minutes and 14 seconds left until a
lubrication cycle begins.
!
HH
ON
OFF
MM : SS
HH : MM
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
C
P1
C
P2
C
C
P3
P
123
FIG. 54
FIG. 55
Prelube / Prelube Delay
In all models a power OFF/ON cycle can be controlled
with the Prelube and Prelube Delay functions.
Prelube
Manual Run Cycle
To run an extra (non-programmed) lubrication cycle, push the Manual Start button.
The Prelube function has been selected. Prelube delay
is set to 00:00:
62
•
Power to the unit cycles OFF then ON.
•
Unit immediately begins a lubrication cycle.
NOTE: Manual Run option is not available while unit is
in Vent Mode.
332305L
Alarms: Firmware Versions 6.01 and Below
Alarms: Firmware Versions 6.01 and Below
Any time a Fault / Warning occurs, a combination of LED’s will illuminate to notify you there is a problem and help
identify the kind of Fault / Warning has occurred.
•
Faults and Warnings will not automatically clear.
•
To clear an fault, press and hold the RESET button on the display button pad for 3 seconds.
•
To clear a warning press and immediately release the RESET button.
Fault / Warning Scenarios
The following pages describe the most likely fault / warnings you could receive.
Alarm Type
Low Level
Warning
What it Looks Like
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
What it Indicates
Solution
Add lubricant to reservoir.
Level of lubricant in
reservoir is low and additional lubricant needs to be After lubricant
is added,
added.
press the
Unit continues to operate RESET button to clear the warning.
as normal for a limited
period of time until a low
level alarm is triggered.
C
P1
332305L
C
P2
C
C
P3
P
123
63
Alarms: Firmware Versions 6.01 and Below
Low Level
Fault
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
Cycle /
Pressure
Warning
C
P2
C
C
P3
P
HH
123
MM
SS
##
ON
OFF
MM : SS
HH : MM
C
P1
C
P2
C
C
P3
P
123
!
Add lubricant to reservoir.
Level of lubricant in
reservoir is low and additional lubricant needs to be After lubricant is
added.
added press
and hold the
Unit stops pumping and
displays amount of accu- RESET button to clear
fault.
mulated time since the
alarm was triggered.
If repriming pump is
required, the low level
alarm time should be
decreased. See A-2:
Advanced Programming,
Low Level Alarm Time
page 51.
System fails to relieve pressure or a lubrication cycle
was not completed in the
user-defined amount of
time.
Examine system to determine if you have a
plugged or broken line or
other component failure,
i.e., divider valve, injector.
Unit will continue to operate for the number of lubrication cycles set by the
warning retry parameter
(see Advanced Programming, page 48).
Press the
RESET button to clear
warning.
If the warning condition
clears itself on the next
automatic lubrication cycle,
the warning is cleared and
the unit continues normal
operation.
64
332305L
Alarms: Firmware Versions 6.01 and Below
Cycle /
Pressure
Fault
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
In cycle mode indicates
that a cycle was not completed in the user-defined
amount of time.
C
P1
C
P2
C
C
P3
P
Examine system to determine if you have a
plugged or broken line or
other component failure,
i.e., divider valve, injector.
Press and
hold the
RESET button to clear
fault.
123
LED corresponding to the
affected sensor input
blinks.
Machine
Count Fault
HH
In pressure mode indicates that unit is over pressurized or a lubrication
cycle was not completed in
the user-defined amount of
time.
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
Could be more than one
sensor alarm at the same
time.
Unit has not received the Examine system to detercorrect number of machine mine if the machine sencounts in the user defined sor is operating properly.
Backup Time.
Press and
hold the
RESET button to clear
fault.
C
P1
332305L
C
P2
C
C
P3
P
123
65
Alarms: Firmware Versions 6.01 and Below
System
Fault
An internal fault has
occurred.
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
Contact Graco Customer
Service.
!
C
P1
Motor Current Warning
C
P2
C
C
P3
P
HH
123
MM
SS
##
ON
OFF
MM : SS
HH : MM
C
P1
66
C
P2
C
C
P3
P
123
!
The measured motor cur- Examine system to make
sure it is operating corrent is above the recomrectly. A blocked line could
mended operating
maximum value. Continued create excessive motor
use at excessive motor cur- current
rents could reduce life or
cause permanent damage. Examine pump to ensure
that it is rotating properly.
If necessary, contact
Graco Customer Service.
332305L
Alarms: Firmware Versions 6.01 and Below
Temperature Warning
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
USB Error
HH
The internal temperature of Ensure the unit is used in
the unit is out of its recom- the correct operating envimended operating range. ronment for the specific
temperature: -13° F to
Use of the unit outside of 158° F (-25° C to 70°C).
the recommended temperature range could cause If necessary contact
Graco Customer Service.
degraded system performance and possible damage.
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
An error occurred during a Read the Troubleshooting
DMS operation.
section of this manual
(page 75) for error numbers and fault descriptions.
C
P1
332305L
C
P2
C
C
P3
P
123
67
Alarms: Firmware Versions 6.02 and Above
Alarms: Firmware Versions 6.02 and Above
Any time a Fault / Warning occurs, a combination of LED’s will illuminate to notify you there is a problem and help
identify the kind of Fault / Warning has occurred. An error message will display and flash every 2 seconds for an
alarm, temperature or current warning and every 10 seconds for all other types of warnings.
•
Faults will not automatically clear. Warnings will clear after a set time, if condition was fixed.
•
To clear an fault, press and hold the RESET button on the display button pad for 3 seconds.
•
To clear a warning instantly press and immediately release the RESET button.
Fault / Warning Scenarios
The following pages describe the most likely fault / warnings you could receive.
Alarm Type
Low Level
Warning
What it Looks Like
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
C
P1
68
C
P2
C
C
P3
P
123
!
What it Indicates
Solution
Add lubricant to reservoir.
Level of lubricant in
reservoir is low and additional lubricant needs to be After lubricant
is added,
added.
press the
Unit continues to operate RESET button to clear the warning.
as normal for a limited
period of time until a low
level alarm is triggered or
until the reservoir is filled
and 30 seconds has
passed at which time the
warning will self-clear.
332305L
Alarms: Firmware Versions 6.02 and Above
Low Level
Fault
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
Cycle Warning
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
C
P1
332305L
C
P2
C
C
P3
P
!
Add lubricant to reservoir.
Level of lubricant in
reservoir is low and additional lubricant needs to be After lubricant is
added.
added press
and hold the
Unit stops pumping and
displays amount of accu- RESET button to clear
fault.
mulated time since the
alarm was triggered.
If repriming pump is
required, the low level
alarm time should be
decreased. See A-2:
Advanced Programming,
Low Level Alarm Time
page 51.
A lubrication cycle was not
completed in the
user-defined amount of
time.
Unit will continue to operate for the number of lubrication cycles set by the
warning retry parameter
(see Advanced Programming, page 48).
Examine system to determine if you have a
plugged or broken line or
other component failure,
i.e., divider valve, injector.
Press the
RESET button to clear
warning.
123
If the warning condition
clears itself on the next
automatic lubrication cycle,
the warning is cleared and
the unit continues normal
operation.
69
Alarms: Firmware Versions 6.02 and Above
Pressure
Warning
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
If the warning condition
clears itself on the next
automatic lubrication cycle,
the warning is cleared and
the unit continues normal
operation.
Cycle Fault
HH
MM
SS
##
!
In cycle mode indicates
that a cycle was not completed in the user-defined
amount of time.
ON
OFF
MM : SS
HH : MM
LED corresponding to the
affected sensor input
blinks.
123
Could be more than one
sensor alarm at the same
time.
C
P1
70
System fails to relieve pres- Examine system to determine if you have a
sure in the user-defined
plugged or broken line or
amount of time.
other component failure,
Unit will continue to oper- i.e., divider valve, injector.
ate for the number of lubriPress the
cation cycles set by the
RESET butwarning retry parameter
(see Advanced Program- ton to clear
warning.
ming, page 48).
C
P2
C
C
P3
P
Examine system to determine if you have a
plugged or broken line or
other component failure,
i.e., divider valve, injector.
Press and
hold the
RESET button to clear
fault.
332305L
Alarms: Firmware Versions 6.02 and Above
Pressure
Fault
HH
MM
SS
##
!
ON
OFF
MM : SS
HH : MM
LED corresponding to the
affected sensor input
blinks.
123
Could be more than one
sensor alarm at the same
time.
C
P1
Machine
Count
Warning
C
P2
C
C
P3
P
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
C
P1
332305L
In pressure mode indicates that unit is over pressurized or a lubrication
cycle was not completed in
the user-defined amount of
time.
C
P2
C
C
P3
P
!
Examine system to determine if you have a
plugged or broken line or
other component failure,
i.e., divider valve, injector.
Press and
hold the
RESET button to clear
fault.
The unit has not received Examine system to determine if the machine senthe correct number of
machine counts in the user sor is operating properly.
defined Backup Time.
Press and
hold the
If the warning condition
RESET butclears itself on the next
automatic lubrication cycle, ton to clear
the warning is cleared and warning.
the unit continues normal
operation.
123
71
Alarms: Firmware Versions 6.02 and Above
Machine
Count Fault
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
Unit has not received the Examine system to detercorrect number of machine mine if the machine sencounts in the user defined sor is operating properly.
Backup Time.
Press and
hold the
RESET button to clear
fault.
C
P1
C
P2
C
C
P3
P
123
System
Fault
An internal fault has
occurred.
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
Contact Graco Customer
Service.
!
C
P1
72
C
P2
C
C
P3
P
123
332305L
Alarms: Firmware Versions 6.02 and Above
Motor
Current
Warning
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
Temperature Warning
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
C
P1
332305L
C
P2
C
C
P3
P
!
The measured motor cur- Examine system to make
sure it is operating corrent is above the recomrectly. A blocked line could
mended operating
maximum value. Continued create excessive motor
use at excessive motor cur- current
rents could reduce life or
cause permanent damage. Examine pump to ensure
that it is rotating properly.
Warning will self-clear any
time after 15 seconds On If necessary, contact
Graco Customer Service.
Time start if the system
correction is made.
The internal temperature of Ensure the unit is used in
the unit is out of its recom- the correct operating envimended operating range. ronment for the specific
temperature: -13° F to
Use of the unit outside of 158° F (-25° C to 70°C).
the recommended temperature range could cause If necessary contact
Graco Customer Service.
degraded system performance and possible damage.
123
73
Alarms: Firmware Versions 6.02 and Above
USB Error
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
An error occurred during a Read the Troubleshooting
DMS operation.
section of this manual
(page 75) for error numbers and fault descriptions.
C
P1
74
C
P2
C
C
P3
P
123
332305L
Fault/Warning Scenarios for Firmware Versions 6.06 and Later for Non-DMS Models and 7.09 and later for DMS Models
Fault/Warning Scenarios for Firmware Versions 6.06
and Later for Non-DMS Models and 7.09 and later for
DMS Models
Alarm Type
Low Power
Warning
What it Looks Like
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
C
P3
P
123
Also if the pump power
cycles on power up for a
minimum of 3 times, the
pump will display a low
power warning.
Low Power
Fault
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
Solution
Check voltage and available current output at the
power source of the
pump.
The unit will continue to
operate for a total of 15
minutes before going into a
Low Power Fault.
C
P1
C
P2
What it Indicates
If there is a voltage drop at
the power source during
operation, the pump will go
into a low power warning
condition.
!
If the warning condition
clears itself, the warning is
cleared and the unit continues operation.
There is a low voltage con- Check voltage and availdition at the power source. able current output at the
power source of the
pump.
Press and hold the
RESET button to clear
fault.
C
P1
332305L
C
P2
C
C
P3
P
123
75
Troubleshooting
Troubleshooting
Problem
Unit does not power on
Cause
Incorrect/loose wiring
Tripped external fuse due to internal
component failure
Unit does not power on (DC models
only)
Solution
Refer to Installation instructions,
page 8.
Contact Graco Customer Service.
Tripped external fuse due to pumping Replace lubricant with pumpable
non-cold weather lubricant in cold
lubricant, rated for environmental
weather -13°F (-25°C)
conditions and application.
Replace fuse.
Unit does not power on (AC models
only)
Can’t set desired ON/OFF times
Unit is not operating based on the
time that was programmed
Tripped internal power supply fuse
due to power supply failure
Contact Graco Customer Service.
Maximum duty cycle is 33% (2 minutes OFF for each minute ON)
Adhere to allowable duty cycle. Contact Graco Customer Support if other
duty cycles are required for application.
Time entered was misinterpreted as
MM:SS instead of HH:MM (or visa
versa)
Verify the unit was programmed as
intended, referencing programming
instructions. Note the dot designation
for hours, minutes, seconds on the
top row of the display.
Reservoir retaining tabs are cracked
or broken
Replace reservoir.
Lubricant leaks past seal located on
the bottom of the reservoir
Reservoir is being pressurized during Ensure vent hole is not plugged.
filling
If problem persists, contact Graco
Customer Service or your local
Graco distributor for assistance.
Unit not pumping during ON cycle,
but controller lights and functions
Failed motor
Replace unit.
Air is trapped in the reservoir
between the follower plate and lubricant
Add grease following Loading Grease
instructions, page 23. Ensure air is
purged.
Follower plate is not going down
Pump takes several minutes before it Pumping non-cold weather lubricant
begins pumping at the highest pump in cold weather -13°F (-25°C)
volume setting (no stroke adjust
spacers installed)
Dim display, unit is not operating
Unit indicates a cycle or pressure
alarm before the lubrication cycle
could complete
76
Add 1 stroke adjust spacer and
adjust lube cycle time to accommodate the difference in pump volume
per stroke.
Tripped internal, resettable fuse due
to internal component failure or sensor short circuit condition
Verify sensor and manual run inputs
have not created a short circuit condition. Cycle power.
The ON Time was not entered correctly
Refer to programming ON Time,
pages 33 and 58.
332305L
Troubleshooting
Problem
Cause
In an Injector System without sensor Vent valve time needs to be configfeedback, unit does not vent properly ured
Solution
Refer to Advanced Programming to
set ON Time, page 48.
Display acts erratically
Faulty cycle/pressure wiring connec- Unplug cycle/pressure cables from
tion to unit
G3. Plug cables in one at a time to
identify the faulty connection.
USB Error 00
Flash drive was removed during
operation
Keep the flash drive plugged in until
the unit has completed the operation.
Flash drive unable to mount (initialize)
•
Pump program setting file not found
USB Error 11
Verify that the pump program setting
folder structure and file are stored
correctly on the flash drive. See Storing Pump Program Settings to the
Flash Drive, page 39 for instructions.
USB Error 12
Pump program settings directory not Verify that the pump program setting
found.
folder structure and file are stored
correctly on the flash drive. See Storing Pump Program Settings to the
Flash Drive, page 39 for instructions.
USB Error 07
Bad pump program settings file
USB Error 13
332305L
Unplug the flash drive and
re-install.
• Cycle power and re-install the
flash drive.
• Retry using a different flash
drive.
• Verify format is FAT32 file system. If not, may need to reformat
flash drive or find a different drive
that has this file system.
If any of the above do not rectify the
error, contact Graco Customer Service.
The pump programs settings file is
corrupt. Restore file to the flash drive.
See Storing Pump Program Settings
to the Flash Drive, page 39 for
instructions.
Settings file is from different firmware Program pump manually or recreate
version
settings file from a pump that has the
same firmware version. See Storing
Pump Program Settings to the Flash
Drive, page 39 for instructions.
77
Troubleshooting
Problem
Cause
Solution
The following operations can be
attempted if another error occurs
using the USB.
•
All other USB errors
•
•
Unplug the flash drive and reinstall.
Cycle power and re-install the
flash drive.
Retry using a different flash
drive.
If any of the above do not rectify the
error, contact Graco Customer Service.
78
332305L
Maintenance
Maintenance
Frequency
Component
Required Maintenance
Daily and at refill
Zerk Fittings
Keep all fittings clean using a clean
dry cloth. Dirt and/or debris can damage pump and/or lubrication system.
Daily
G3 Pump Unit and Reservoir
Keep pump unit and reservoir clean
using a clean dry cloth.
Daily
Display
Keep display clean using a clean dry
cloth.
Monthly
External Wiring Harness
Verify external harnesses are secure.
332305L
79
Parts - 2 Liter Models
Parts - 2 Liter Models
Follower Plate Only
43
44
40b
Low Level Grease Models
45
42
41
35
57
27 1
40a
60
16
15
36
23
37 3
13
14
12
Low Level
Oil Models
18
1
67
21
31
66
33
17 3
42
34
3
30
1 Torque to 4 in. lbs (0.45 N.m)
2 Torque to 30 in. lbs (3.4 N.m)
3 Torque to 50 in. lbs (5.6 N.m)
80
332305L
Parts - 4 Liter and Larger Models
Parts - 4 Liter and Larger Models
Follower Plate Models
40b
43
44
40a
41
42
Low Level Grease Models Only
45
36
Auto-Fill Shut Off Models
82
35
83
61
81
57
27 1
85
60
84
16
56
62
23
13
14
12
87
36
88
40c
74
15
18
37
Low Level Oil Models
3 21
31
1
67
33
89
73
72
17 3
34
45
66
3
1 Torque to 4 in. lbs (0.45 N.m)
30
4 2
2 Torque to 30 in. lbs (3.4 N.m)
3 Torque to 50 in. lbs (5.6 N.m)
332305L
81
Parts
Parts
Ref
1
Part
Description
BASE, three pump housing
Qty
37
40a 24E984
278142 COVER, bottom, with seal
1
4
115477 SCREW, mach, torx pan hd
9
12
13
1
2
14
PLATE, ricer
1
15
BEARING, ball
1
16
PADDLE, stirring, 2 Liter models
without follower plate, included in
Kit 571044
PADDLE, stirring, 4 Liter models
and larger without follower plate
PADDLE, stirring, 2 Liter models
with follower plate, included in Kit
571045
PADDLE, stirring, 4Liter models
and larger with follower plate
PUMP, element, included in Kit
571041
SPACER, stroke adjust, included in
16F368
Kit 571041
Part
1
3
RECT-RING, included in Kit
127079
571042, 571069, 571179
O-RING, included in Kit 571042,
132524
571044, 571045, 571069, 571179
Ref
Description
Qty
123741 FITTING, Zerk, grease
1
RESERVOIR, 2 liter, grease,
included in Kit 571042, 571069
RESERVOIR, 2 liter, oil, included in
40b 16G021
Kit 571179
RESERVOIR, 4 liter, grease,
40a 24B702
included in Kit 571183
RESERVOIR, 4 Liter, oil, included
40b 16G020
in kit 571182
40c
1
1
1
1
17F484 RESERVOIR, 4 Liter, G3 AFSO
1
278139 SEAL, follower plate, 2 liter models
1
16F472 SEAL, follower plate, 4 liter models
2
41
1
42
PLATE, follower
1
43
ROD, follower plate
1
44
SPRING, compression
1
1
1
45† 24D838 BAFFLE, low level, 2 liter models
1
†
24E246 BAFFLE, low level, 4 liter models
1
†
24F836 BAFFLE, low level, 8 liter models
1
2
†
24F923 BAFFLE, low level, 12 liter models
1
2
†
24F924 BAFFLE, low level, 16 liter models
1
23 278942 PADDLE, low level
1
56
127144 SEAL, oval
1
27
123025 SCREW, M6
1
57
117156 BEARING, sleeve
1
30
‡
258697 BOARD, circuit, Max, models
1
58 196548 LABEL
1
™
‡ 262463 BOARD, circuit, Max, DMS
models
1
60
2
17
18
21
31
278145 PLUG, pump, 3/4-16
119228 SCREW, machine, flat head
1
1
1
34
1
35
36
82
16A073 LABEL, overlay
WIPER, stirring, models without follower plate, included in Kit 571044
WIPER, stirring, models with follower plate, included in Kit 571045
LABEL, brand
RESERVOIR, mid-section (see quantity
by size / model below)
2
33 16A579 LABEL, safety
16D984 WASHER, low level models
61
8 Liter models
1
12 Liter models
2
16 Liter models
3
ADAPTER, reservoir
1
1
62
1
1
66
126417 NUT, oil
1
67
24N806 FLOAT, oil
1
332305L
Parts
Ref
Part
Description
Qty
72
PLATE, baffle, low level
1
73
SCREW, machine
2
74
SPRING, plate, valve, reset
1
81
VALVE, AFSO
1
82
BOLT, mounting
1
83
PACKING, o-ring
1
84
PACKING, o-ring
1
85
SEAL, upper, reservoir
1
87
SEAL, lower, reservoir
1
88
SPACER, seal, base
1
89
PLATE, valve
1
127783
127780
200 127781
127782
CABLE,15 ft (4.5 m), SOOW
w/7pos, 3 pin, 90 deg
CABLE, 15 ft (4.5 m), SOOW w/7
pos, 5 pin, 90 deg
CABLE, 20 ft (6.1 m), SOOW, w/7
pos, 5 pin, 90 deg
CABLE, 30 ft (9.1m) SOOW, w/7
pos, 5 pin, 90 deg
16U790 CABLE, DIN, bare)
CABLE, M12, 15 ft., 4 wire, straight
male to flying leads
201
CABLE, M12, 15 ft., 4 wire, straight
124333
male to female
CONNECTOR, Eurofast, fem,
124301
straight, 4Pin
124300
1
1
1
1
1
1
1
202 124594
CONNECTOR, Eurofast, 4 Pin
1
124595 CONNECTOR, Eurofast, 5 Pin
1
 Replacement Danger and Warning labels, tags and
cards are available at no cost.
 Also order Ref 27, Part No. 123025 and Ref 60, Part
No. 16D984
‡ Also order Ref 31, Part No. 119228 and Ref 34, Part
No. 16A073
Pressure Relief Valves
Important Information regarding Pressure Relief
Valve 16C807.
 Pressure Relief Valve 16C807 can only be used on
the G3 Pump. It is not intended for use with any other
products.
The pressure relief valve uses a
pressure adjustment screw (a) to
set the pressure release point. It
is not intended as a way to
relieve pressure during normal
operation, but as a protective
measure in the event there is an
unintended pressure increase in
the system. Do not use this pressure relief valve a means of
relieving pressure in day-to-day,
normal cycle operation.
a
b
ti15644
a = adjustment screw
b = locking nut
The pressure adjustment screw
will require periodic adjustments.
Whenever the valve is set/adjusted (after the set point is
found) it is important to ensure that the valve is not bottomed out and there is at least 1/2 turn of adjustment
remaining. This is determined by turning the screw (a)
1/2 turn and then back turning it out again.
NOTE: Turning adjustment screw (a) clockwise
increases pressure.
Part
Description
VALVE, pressure relief, 500-3500 psi (3.44
MPa, 34.4 bar - 24.1 MPa, 241 bar), Set pres16C807
sure 3000 psi + 10% (20.68 MPa, 206.8 bar +
10%) Included in Kit 571028
VALVE, pressure relief, 750 psi (5.17 MPa,
563156
51.71 bar)
VALVE, pressure relief, 1000 psi (6.89 MPa,
563157
68.95 bar)
VALVE, pressure relief, 1500 psi (10.34 MPa,
563158
103.42 bar)
VALVE, pressure relief, 2000 psi (13.78 MPa,
563159
137.89 bar)
VALVE, pressure relief, 2500 psi (17.23 MPa,
563160
172.36 bar)
VALVE, pressure relief, 3000 psi (20.68 MPa,
563161
206.84 bar)
VALVE, pressure relief, 5500 psi (37.92 MPa,
563190
379.21 bar)
Qty
1
1
1
1
1
1
1
1
† Also order Ref. 57, Part No. 117156 when ordering
this part.
332305L
83
Parts
Fuses
Part
Description
Qty
571039 FUSE, 12 volt DC
1
571040 FUSE, 24 volt DC
1
Installation and Repair Kits
Kit No.
Description
571026 KIT, output union, 3 pump
571063 KIT, output union, 2 pump
KIT, return to reservoir NPT, includes pres571028
sure relief valve 16C807
KIT, return to reservoir BSPP, includes pres571071
sure relief valve 16C807
571030 KIT, remote manual run, 12 volt DC
571031 KIT, remote manual run, 24 volt DC
KIT, remote manual run, 12 volt DC, with
571032
cable
KIT, remote manual run, 24 volt DC with
571033
cable
571036 KIT, cover with “G” label
571041 KIT, pump element, includes Ref 17, 18, 33
KIT, repair, 2 liter reservoir, includes Ref 13,
571042
36, 40
KIT, repair, 2 liter reservoir, for models with
571069
follower plate, includes Ref 13, 36, 40
KIT, replacement, paddle, 2 liter, for models
571044 without follower plate, includes Ref 13, 16,
35, 57
KIT, replacement, paddle, 2 liter, for models
571045 with follower plate, includes Ref 13, 16,
35,40a, 42, 57
KIT, replacement, paddle, 4-16 liter, for mod571046 els without follower plate, includes Ref 13,
16, 35, 57
KIT, replacement, paddle, 4 liter, for models
571047 with follower plate, includes Ref 13, 16, 35,
57
571058 KIT, output adapter, NPT
571070 KIT, output, adapter, BSPP
571060 KIT, fill, zerk, leak proof
KIT, repair, reservoir oil, 2 liter models,
571179
includes Ref 13, 36, 40b
KIT, repair, reservoir, oil 4 liter models,
571182
includes Ref 13, 36, 40b
KIT, repair, reservoir, grease, 4 liter models,
571183
includes Ref 13, 36, 40b
127685 RING, fixing for CPC connector
16G02
CAP, filler
2
84
Manual
Number
3A0523
3A0525
3A0528
NA
3A0533
3A0534
3A0535
3A0522
NA
3A0534
NA
1
332305L
Technical Data
Technical Data
A
Pump Output Pressure
Fill Inlet Pressure
Power
100-240 VAC
12 VDC
24 VDC
Outputs - Alarm Relay
Rated Load
Max Operation Voltage
Max Operating Current
Max Switching Capacity
Min Permissible Load
Outputs - Vent Valve
Required Vent Valve Type
Output Voltage
100/240 VAC
12 VDC
24 VDC
Max Operating Current
Max Operating Power
Inputs - Cycle Pressure, 1, 2, 3, Machine Count
Required Switch Type
Sensor Voltage
100/240 VAC
12 VDC
24 VDC
Load Current
100/240 VAC
12 VDC
24 VDC
Maximum Residual Voltage
100/240 VAC
12 VDC
24 VDC
Maximum Off Current
100/240 VAC
12 VDC
24 VDC
Input Impedance
Response Time
Cycle Rate
332305L
5100 psi (35.1 MPa, 351.6 bar)
5000 psi (34.4 MPa, 344.7 bar)
88 - 264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz,
Single phase, inrush/locked rotor, max 40A (1ms)
9 - 16 VDC; 5 A current, 60 W, inrush/locked rotor 12 A
18 - 32 VDC; 2.5 A current, 60 W, inrush/locked rotor 6 A
Resistive: 0.4 A at 125 VAC, 2 A at 30 VDC
Inductive: 0.2 A at 125 VAC, 1 A at 30 VDC
Resistive: 250 VAC, 220 VAC
Inductive: 250 VAC, 220 VDC
Resistive: 3 A (AC), 3A (DC)
Inductive: 1.5 A (AC), 1.5 A (DC)
Resistive: 50 VA, 60 W
Inductive: 25 VA, 30 W
Resistive: 10 µA, 10m VDC
Inductive: 10 µA, 10m VDC
Normally closed
24 VDC
Input Voltage
Input Voltage
2A
48 W
Normally open (sink, source, or dry contact)
24 VDC
Input Voltage
Input Voltage
22mA @ 24 VDC
11mA @ 12 VDC
22mA @ 24 VDC
4V
2V
4V
1.5 mA
1 mA
1.5 mA
1.1 K
60 ms
8.0 Hz (50% duty cycle)
85
Technical Data
Fluid
Grease Models
Oil Models
Pumps
Pump Output
Pump Outlet
Reservoir Size
IP Rating
Sensor Inputs
Ambient Temps
Weight (Dry - includes power cord and plug)
Without follower plate
With follower plate
Wetted Parts
Sound Data
Grease NLGI 000 - #2
At least 40 cSt oil.
Up to 3
0.12 in.3 (2 cm3) / minute per outlet - 2 spacers
0.18 in.3 (3 cm3) / minute per outlet - 1 spacer
0.25 in.3 (4 cm3) / minute per outlet - 0 spacers
1/4-18 NPSF. Mates with 1/4-18 NPT male fittings
2, 4, 8, 12, 16 Liters
IP69K
3 (any of pressure or cycle)
1 (machine count)
-40°F - 158°F (-40°C to 70°C)
13.3 lbs (6.03 kg)
14.2 lbs (6.44 kg)
nylon 6/6 (PA), amorphous polyamide, zinc plated steel,
carbon steel, alloy steel, stainless steel, nitrile rubber
(buna-N), bronze, nickel plated alnico, chemically lubricated acetal, aluminum, PTFE
<60 dB
California Proposition 65
WARNING: This product can expose you to chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm. For more information, go to
www.P65warnings.ca.gov.
Dimensions
Model
2L
4L
8L
12L
16L
86
Height
Width
Depth
Inches
cm
Inches
cm
Inches
cm
13.25
14.50
18.50
23.00
27.50
33.65
36.83
47.00
58.42
69.85
8.00
9.25
9.25
9.25
9.25
20.32
23.50
23.50
23.50
23.50
9.00
10.00
10.00
10.00
10.00
22.86
25.40
25.40
25.40
25.40
332305L
Technical Data
Mounting Pattern
(For correct mounting configuration, choose either Option 1 or Option 2). See P/N 126916 template.
Option 1
0.367inch
9.3 mm
7.087 inch
180.0 mm
2x Ø 0.366 inch
9.3 mm
1.180 inch
30.0 mm
3.268 inch
83.0 mm
3.544 inch
90.0 mm
Option 2
0.722 inch
18.3 mm
6.378 inch
162.0 mm
2x Ø 0.366 inch
9.3 mm
0.708 inch
18.0 mm
3.740 inch
95.0 mm
3.189 inch
81.0 mm
FIG. 56
332305L
87
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 materials 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 PURPOSE, 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
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
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 in 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.
Original instructions. This manual contains English. MM 332305
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision L, November 2020

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