Graco 3A6714B, G-Mini Pump Instructions

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Instructions

G-Mini

Pump

3A6714B

EN

For dispensing NLGI Grades #000 to #2 greases. For professional use only.

Not approved for use in explosive atmospheres or hazardous (classified) locations.

Models, page 3

4061 psi (28 MPa, 280 bar) Maximum Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual before using the equipment.

Save these instructions.

2

Contents

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 7

Divider Installation Remote............................. 7

CSP Valve Installation with Bracket ............... 7

Choose an Installation Location . . . . . . . . . . . . . . 8

System Configuration and Wiring . . . . . . . . . . . . 8

Fuses.............................................................. 8

Recommendations for Pump Usage in

Harsh Environments................................. 8

Wiring and Installation Diagrams.................... 9

Manual Run Button . . . . . . . . . . . . . . . . . . . . . . 11

Proximity Switch. . . . . . . . . . . . . . . . . . . . . . . . . 11

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 12

Disconnect and isolate all power supplies.... 12

Connect to Auxiliary Fittings . . . . . . . . . . . . . . . 12

Pressure Relief Valves ................................. 12

Pressure Relief Valves. . . . . . . . . . . . . . . . . . . . 12

Set Pump Outlet Volume . . . . . . . . . . . . . . . . . . 13

Load Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Change Greases .......................................... 14

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Non Controller Operation . . . . . . . . . . . . . . . . . . . 16

Low-Level Output Option.............................. 16

Controller Operation . . . . . . . . . . . . . . . . . . . . . . . 17

RUN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SETUP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ON TIME Configuration (Minutes) ................ 18

ON TIME Configuration (Cycles) .................. 19

OFF TIME Configuration (Min./Hrs).............. 19

ADVANCED PROGRAMMING . . . . . . . . . . . . . 20

Advanced Programming Menu Descriptions 20

Alerts and Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . 23

Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Alert and Alarm Scenarios . . . . . . . . . . . . . . . . . 24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Reservoir Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Pump Element Kits . . . . . . . . . . . . . . . . . . . . . . . 27

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Pump Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Universal Bracket Mount . . . . . . . . . . . . . . . . . . 31

CSP Valve Bracket Mount . . . . . . . . . . . . . . . . . 31

Technical Specifications . . . . . . . . . . . . . . . . . . . . 32

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 34

3A6714B

Models

Models

Model

25R800

25R801

25R802

25R803

25R804

25R805

25R806

25R807

25R808

25R809

25R810

X

X

X

X

0.5 L 1 L

X

X

X

X

X

X

X

Reservoir

Non-

Controller Controller

X

X

X

X

X

X

X

X

X

X

X

Voltage

12VDC 24VDC

X

X

X

X

X

X

X

X

X

X

X

Power

Input

CPC

CPC

CPC

CPC

CPC

CPC

CPC

CPC

CPC

CPC

CPC

Low

Level

X

X

X

X

X

X

X

X

X

X

X

Cycle

Feedback

Input

Pump

Element

Quantity Heater

M12

1

1

M12

M12

M12

M12

1

2

1

1

X

X

X

M12

M12

1

1

1

1

1

3A6714B 3

Warnings

Warnings

The following warnings are for the setup, use, 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

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.

4

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 Specifications

in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See

Technical

Specifications

in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheets (SDSs) 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.

3A6714B

3A6714B

Warnings

WARNING

PRESSURIZED EQUIPMENT HAZARD

Over-pressurization can result in equipment rupture and serious injury.

• A pressure relief valve is required at each pump outlet.

• Follow the

Pressure Relief Procedure

in this manual when servicing equipment.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many cleaning solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

• Use only compatible solvents to clean plastic structural or pressure-containing parts.

See Technical Specifications

in all equipment manuals for materials of construction. Consult the solvent manufacturer for information and recommendations about compatibility.

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.

• 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. Protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

5

6

Installation

Installation

Component Identification

E

F IG . 1:

Key:

A Reservoir

B Venting Tube

C Follower Plate

D Pump Element

E Zerk Inlet Fill Fitting

F Cycle Indicator Connector (Controller model only)

G CPC Connector

H Controller

J Return to Reservoir

A

B

C

D

J

J

F

G

H

3A6714B

Typical Installation

Divider Installation Remote

L

N

K

F IG . 2:

CSP Valve Installation with Bracket

M

R

S

L

P

Installation

T

R

F

IG

. 3:

K Connection to fused power source

L Pressure relief valve (required for each outlet)*

See Pressure Relief Valves , page 12

M Proximity switch cable

N Series progressive divider valves (Divider Installation)

P Connection to lube points

R

Proximity switch, see page 11

S

Bracket, see page 8

T

Direct Mount CSP Hose, see page 8

U CSP valves

U

*User Supplied

K

3A6714B 7

Installation

Choose an Installation Location System Configuration and

Wiring

AUTOMATIC SYSTEM ACTIVATION HAZARD

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

This device has an automatic timer that activates the pump lubrication system when power is connected or when exiting the programming function. Before you install the lubrication pump or remove it from the system, disconnect and isolate all power supplies and relieve all pressure.

• Select a location that will support the weight of the pump and lubricant, as well as all plumbing and electrical connections.

• Refer to the two mounting hole layouts provided in the Mounting Pattern section of this manual, page

31.

• Use designated mounting holes and provided configurations only.

• Use the two fasteners (included) to secure the pump to the mounting surface.

Some installations may require an additional pump bracket.

Mounting Bracket

Part No

26C826

26C825

Description

Universal Bracket

CSP Mounting Bracket

Direct Mount CSP Hose Kits

Part No

26C956

26C957

Description

1/4 NPT (Pressure Relief Outlet) to 1/8

NPT (CSP Inlet)

1/4 NPT (Pressure Relief Outlet) to 1/8

BSPT (CSP Inlet)

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Fuses

NOTICE

Fuses (user supplied) are required on all DC models.

To avoid equipment damage:

• Never operate pump DC models without a fuse installed.

• A fuse of the correct amperage 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 the input voltage and the corresponding Graco Kit number.

Fuse Value

10A

5A

7.5A

Graco Kit No.

26C916

26C917

571039

Applicable

Model

25R802

25R803

25R806

25R809

25R810

25R800

25R807

25R801

25R804

25R805

25R808

Recommendations for Pump Usage in

Harsh Environments

• Use pump with CPC style power cable.

• Use a corrosion preventative electrical grease on all contacts.

CSP Mount Kits

Part No

26C958

26C959

Description

Kit, CSP Mount, NPT

Kit, CSP Mount, BSPT

8 3A6714B

Wiring and Installation Diagrams

NOTE: Wire colors provided on these pages refer only to the Graco power cable.

NOTICE

The stirring paddle should rotate clockwise (as viewed

from the top) (F IG . 4) when power is applied. Allowing

the stirring paddle to rotate counterclockwise damages the pump’s internal components.

If the stirring paddle is rotating counterclockwise, stop the pump immediately. Check that the wiring is correct and make any necessary changes.

If the motor does not run after power is supplied, check the pump wiring.

Power CPC DC - 5 Wire (Non-Controller)

Pin Out

1 Not Used Not Used

2 -VDC Black

3 +VDC Red

4 Low-Level

5 Low-Level

6 Not Used

7 Not Used

White

Orange

Not Used

Green

Installation

F IG . 4

3A6714B

F

IG

. 5

9

F IG . 6

10

Installation

Power CPC DC - 5 Wire (Controller)

Pin Out

1 Not Used Not Used

2 -VDC Black

3 +VDC Red

4 LED+

5 Button

6 Not Used

7 LED-

White

Orange

Not Used

Green

Divider Valve Indicator Cycle Inputs (M12)

See Technical Specifications , page 32 for ratings.

F IG . 7

3A6714B

F IG . 8

3A6714B

Part No. 124333: Cable Pin Out (M12) for

5 m Cable

Wire Colors (F

IG

. 8)

Item No.

Color

1

2

3

4

Brown

White

Blue

Black

Installation

Manual Run Button

Part No.

25C981

25C982

Description

Manual Run Button, 12V

Manual Run Button, 24V

Proximity Switch

NOTE: Reference ILE buyer’s guide for appropriate PNP proximity switches and cables.

11

Setup

Setup

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

Connect to Auxiliary Fittings

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.

Disconnect and isolate all power supplies.

Relieve pressure in the system using two wrenches working in opposite directions on the pump element and pump element fitting to slowly loosen fitting only until the fitting is loose and no lubricant or air is leaking from fitting.

NOTE: When loosening the pump element fitting, do not loosen the pump element. Loosening the pump element changes the output volume.

NOTICE

Do not attach unsupported equipment to auxiliary fittings such as fill ports and pump element. Attaching unsupported equipment to these fittings can result in irreparable housing damage.

• Always use two wrenches working in opposite directions when connecting anything to pump element or auxiliary fittings. See F IG . 9 for an example.

• Torque pump element fittings to 50 in-lb (5.6 N•m).

• Torque pump element to 65 in-lb (7.3 N•m) when connecting to the housing.

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 each pump outlet to alleviate unintended pressure rises in the system and protect the 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.

• Install a pressure relief valve before any auxiliary fitting.

NOTE: A pressure relief valve may be purchased from

Graco. See Pressure Relief Valves , page 12.

Pressure Relief Valves

Part No.

571028

Description

Kit, Adj. Pressure Relief

F IG . 9

12 3A6714B

Setup

Set Pump Outlet Volume

1.

Follow the

Pressure Relief Procedure , page 12.

2.

Use a wrench and turn the pump element counterclockwise to remove the entire pump element.

4.

Re-install the pump element into the pump base, ensuring that the first thread of the element engages correctly.

NOTE: It may be necessary to repeat the pump outlet volume setup procedure after the pump is operating to adjust the volume of the dispensed fluids.

5.

Use a wrench and tighten the pump element fitting.

Torque to 50 in-lb (5.6 N•m).

NOTE:

• The dispensed volume amount varies depending upon external conditions, such as lubricant temperature and back pressure from downstream connections.

• Use the volume adjustment process in conjunction with setting the ON time of the pump to control the output volume.

• The volume adjustment process should be used as a starting point for dispensing the desired lubrication volume.

F IG . 10

3.

Replace the current spacer with the desired spacer.

Spacers

25N814

18A317 mm

1.5

4.6

Cubic In.

0.183

0.0915

Cubic cm

3.0

1.5

NOTE: A spacer is required for operation. Only one

Graco spacer can be used at a time. The pumps from the factory have a spacer (25N814) installed on the pump element.

Pump Element Kits (page 27) come

with a spacer. The spacer may be replaced depending upon the required output volume.

Load Grease

To ensure optimal performance from the pump:

• Use only NLGI #000 - #2 greases appropriate for the application, automatic dispensing, and the equipment’s operating temperature. Consult with the machine and lubrication manufacturers for details.

• Fill the reservoir using a hand operated pump, pneumatic pump or electric transfer pump.

• Do not overfill.

• Do not operate the pump without having a reservoir attached.

NOTICE

• Always clean fitting (E) with a clean dry cloth prior to filling the reservoir. Dirt and/or debris can damage pump and/or lubrication system.

• Use care when filling the reservoir using a pneumatic or electric transfer pump to avoid pressurizing and breaking the reservoir.

3A6714B 13

Setup

1.

Connect the fill hose to the Zerk Inlet Fill Fitting (E)

(F

IG

. 11).

NOTE: The venting tube (B) should not be used as an overfill indicator (F

IG

. 12).

B

E

F IG . 11

2.

For higher viscosity fluids, start the pump, per the controller instructions, to rotate the stirring paddle during filling to prevent air pockets from forming in the grease.

For models using an external controller, start the pump operation following the controller instructions.

3.

Fill the reservoir with NLGI grease to the MAX line

(F IG . 12).

F

IG

. 12

4.

Remove the fill hose.

Change Greases

Always use compatible grease when changing grease.

14 3A6714B

Setup

Priming

It is not necessary to prime the pump every time the pump is filled. The pump only requires priming the first time it is used, or if it is allowed to run dry.

1.

Loosen the pump element fitting (F IG . 13).

NOTE: When loosening the pump element fitting, do not loosen the pump element. Loosening the pump element changes the output volume and causes leakage.

F

IG

. 13

2.

Only run the pump until air is no longer dispensed with the lubricant out of element fitting (F

IG

. 14).

F

IG

. 14

3.

Tighten the pump element fitting using two

wrenches working in opposite directions (F

IG

. 15).

F IG . 15

3A6714B 15

Non Controller Operation

Non Controller Operation

The pump can be controlled using an external, user supplied, controller.

NOTE:

• When using an external controller, Pump ON (Run)

Time should be set for no longer than 30 minutes.

• In most cases, Pump OFF (Rest) Time should be twice as long as Pump ON (Run) time. If alternative

ON / OFF times are required, contact Graco Customer Service for assistance.

Low-Level Output Option

Pumps without controllers include a Low-Level Output

Option. The low-level signal is monitored across PINS 4 and 5. For the locations and wiring information for PINS

4 and 5, see the

Wiring and Installation Diagrams

,

page 9.

Typical Low-Level Output Response with Low-Level Fluid

F IG . 16

16 3A6714B

Controller Operation

Controller Operation

Control Panel Overview (F

IG

. 17)

ON TIME

• In SETUP MODE, the LED illumi-

• nates when ON TIME duration or cycles are set up.

• A dot illuminates under MM on the display.

• The ON TIME range is 1 to 30 minutes, or 1 to 99 cycles.

In RUN MODE, the LED illuminates during the ON TIME sequence.

DISPLAY

• Upon entering SETUP MODE, the first digit in the display begins to blink.

• In RUN MODE, the programmed

ON TIME, CYCLES or OFF TIME displays and counts down to zero.

MANUAL RUN / ENTER

• In SETUP MODE, press this button to save the entry, move the cursor in the display one field to the right or to the next setup step.

• In RUN MODE, press this button to start a manual run cycle.

OFF TIME

• In SETUP MODE, the LED illuminates when OFF TIME duration is set up.

• A dot illuminates under HH on the display.

• The OFF TIME range is 15 / 30 / 45 min or 1 to 99 hours.

• The LED illuminates when OFF TIME sequence is running.

ALARM

The LED illuminates when an alert / alarm event occurs.

Most alerts/alarms occur during ON TIME MODE.

However, if a Low-Level alert triggers near the end of an

ON TIME cycle, the alert will display while the controller is in OFF TIME MODE. A software error occurring when the controller is operating in the OFF TIME MODE will also activate the alarm LED.

UP and DOWN ARROWS

• Hold both the UP and

DOWN arrow buttons together for 3 seconds to enter SETUP MODE.

• In SETUP MODE, the UP and DOWN arrows increase or decrease time and cycle setting values shown on the display.

• In RUN TIME MODE, pressing the UP arrow/CANCEL button terminates the lubrication period.

F IG . 17

3A6714B 17

Controller Operation

The controller operates in two modes; RUN MODE and

SETUP MODE. Each mode has multiple functions.

RUN MODE

RUN MODE performs two functions while monitoring

Alert/Alarm conditions: ON TIME and OFF TIME.

• In ON TIME the motor is running and the lubrication is delivered. ON TIME can be configured to be active for a period of time in minutes or a period of lube cycles (cycle or proximity switch is required).

• In OFF TIME the motor is not running. This is a period where no lubrication is delivered. OFF TIME can be configured for 15 / 30 / 45 min. or 1 to 99 hours.

By default, units with controllers are set to operate with an ON TIME period of five (5) minutes and an OFF

TIME period of one (1) hour.

Once an ON TIME lubrication period begins, it can be terminated by pressing the UP arrow/CANCEL button.

While in RUN MODE the controller monitors Alert/Alarm conditions. See

Alert and Alarm Scenarios , page 24 for full descrip-

tions.

SETUP MODE

Press both the UP and

DOWN arrow buttons together for 3 seconds to enter SETUP MODE.

The first digit on the display begins to blink. This indicates SETUP MODE. After entering SETUP Mode, if no activity is detected, after 60 seconds a timeout occurs and the controller resumes in

RUN MODE.

ON TIME Configuration (Minutes)

The first configuration in SETUP MODE is programming the ON TIME.

Notice the following on the controller:

The LED next to the

Clock in the ON field illuminates.

The first digit on the display begins to blink.

A dot on the display under the MM illuminates.

This confirms that the controller is ready for the first digit to be configured for ON TIME in Minutes (MM).

NOTE: The ON TIME can be configured between 1 to

30 minutes.

1.

Press the UP or DOWN arrows to select the first digit.

2.

Press the ENTER button to save the selection.

After the ENTER button is pressed, the second digit begins to blink. The ON LED and MM dot remains lighted.

This confirms that the second digit for ON TIME is being configured in Minutes (MM).

18 3A6714B

Controller Operation

3.

Press the UP or DOWN arrows to select the second digit.

4.

Press the ENTER button to save the selection.

The controller automatically switches to OFF TIME configuration.

ON TIME Configuration (Cycles)

NOTE: The proximity switch accessory must be installed and Cycle Count enabled in Advanced Programming

(page 20) before the number of cycles can be config-

ured in SETUP MODE.

Notice the following on the controller:

The LED next to the

Clock in the ON field illuminates

The display reads “CY” to identify that the ON

TIME is configured for

Cycles Counts.

NOTE: The number of cycles counts can range from 1 to 99.

1.

Press the ENTER button to advance the display.

The first digit on the display begins to blink. This confirms that the controller is ready for the cycle count to be configured.

2.

Press the UP or DOWN arrows to select the first digit.

After the ENTER button is pressed, the second digit begins to blink. The ON LED remains lighted.

This confirms that the second digit for ON TIME is being configured in Minutes (MM).

4.

Press the UP or DOWN arrows to select the second digit.

5.

Press the ENTER button to save the selection.

The controller automatically switches to OFF TIME configuration.

OFF TIME Configuration (Min./Hrs)

Notice the following on the controller:

The LED next to the

Clock in the OFF field is lighted.

The first digit on the display begins to blink.

A dot on the display under the HH illuminates.

This confirms that the controller is ready for the first digit to be configured for OFF TIME in Hours (HH).

NOTE : The OFF TIME must be configured between 15 min, and 99 hours.

1.

Press the UP or Down arrows to select the first digit.

3.

Press the ENTER button to save the selection.

2.

Press the ENTER button to save the selection.

3A6714B 19

Controller Operation

After the ENTER button is pressed, the second digit begins to blink. The OFF

LED and HH dot remain lighted.

This confirms that the second digit for OFF TIME is being configured in Hours

(HH).

3.

Press the UP or DOWN arrows to select the second digit.

4.

Press the ENTER button to save the selection.

The controller automatically switches to RUN MODE.

ADVANCED PROGRAMMING

The Seven Advanced Programming Menu Descriptions are:

• A1 - PIN Entry Enable/Setting Up the PIN Code, page 20

A2 - Prelube and Delay, page 22

• A3 - Low-Level Alert Duration, page 22

• A4 - Missed Cycle Threshold, page 22

• A5 - Low-Level Power Cycle Retry, page 22

• A6 - Low-Level Alert Enable, page 22

• A7 - Cycle Count Enable, page 22

To access ADVANCED PROGRAMING:

1.

Press both the UP and

DOWN arrow buttons for

3 seconds to enter

SETUP MODE.

2.

In SETUP MODE, press and hold the UP arrow for 10 seconds.

After entering ADVANCED PROGRAMMING, if no activity is detected for 60 seconds, a timeout occurs and the controller resumes RUN MODE.

Press the ENTER button to advance to the configurable portion of the specific settings.

1.

Press the UP or DOWN arrows to configure the selection.

For ON or OFF selection:

ON: UP arrow

OFF: DOWN arrow

2.

After completing configuration, press the

ENTER button to save and proceed to the next ADVANCED PROGRAMMING settings.

After all of the ADVANCED PROGRAMMING settings are configured, press the ENTER button to return the controller to RUN MODE.

Advanced Programming Menu Descriptions

A1 – PIN Entry Enable/Setting Up the PIN Code

A PIN Code provides additional controller security by requiring that a PIN Code be entered before gaining access to SETUP MODE.

NOTE: The PIN Code can be configured to be any number between (and including) 00 and 99.

To set up the PIN Code:

1.

Follow Steps 1 and 2 of ADVANCED PROGRAM-

MING , (page 20).

2.

When A1 appears on the display, press the ENTER button. Either On (PIN Code

ON) or OF (PIN Code OFF) displays.

• On (ON) - Select On to configure the controller to require that a PIN Code be entered prior to accessing SET UP Mode.

-

The display reads A1. This confirms that the controller is in the

ADVANCED PROGRAMMING settings.

20 3A6714B

Entering a PIN Code in the Controller

After the controller is configured for PIN entry, to access

SETUP MODE:

1.

Follow Steps 1 and 2 of

ADVANCED PROGRAM-

MING , (page 20).

2.

Pn appears on the display.

Controller Operation

OF (OFF) - Select OF to configure the controller to not require a PIN code. Press the

ENTER button again to set the OF (OFF) option.

3.

The first digit on the display begins to blink. This confirms that the controller is ready to select the first number of the PIN

Code.

4.

Press the UP or Down arrows to select the first digit.

5.

Press the ENTER button to save the selection.

After the ENTER button is pressed, the second digit begins to blink.

This confirms that the second digit for the PIN Code is ready to be configured.

6.

Press the UP or Down arrows to select the second digit.

7.

Press the ENTER button to save the selection.

8.

The controller automatically advances to the A2 screen.

3.

Press the ENTER button to advance the display.

4.

The first digit on the display begins to blink. This confirms that the controller is ready for the first number of the PIN Code to be entered.

5.

Press the UP or Down arrows until the first digit of the PIN Code displays.

6.

Press the ENTER button to save the entry.

7.

After pressing the ENTER button, the second digit begins to blink. This confirms that the controller is ready for the second number of the PIN Code to be entered.

8.

Press the UP or Down arrows until the second digit of the PIN Code displays.

9.

Press the ENTER button to save the entry.

10. The ON TIME configuration screen displays. See

SETUP MODE , ON TIME Configuration (Minutes) , page 18 for additional information.

3A6714B 21

Controller Operation

A2 – Prelube and Delay

The Prelube Delay option configures the controller to set the amount of time before the Prelube cycle begins. The duration of time begins after power has been restored to the controller. This value can range from 0 to 60 minutes

(default: 0).

The Prelube function determines operation of the pump when power is applied. It can be set to ON or OFF.

• OF (OFF) (default) – The unit resumes at the point in the lubrication cycle it was at when power was disengaged.

• On (ON) – The unit begins a pump cycle once power is restored.

When On is selected and the Enter button is pressed, the controller is ready for a Prelube delay to be config-

ured. See ADVANCED PROGRAMMING instructions, page 20.

A3 – Low-Level Alert Duration

The Low-Level Alert Time configures the controller to set the duration of time that a Low-Level Alert exists with the pump running before escalating to an Alarm.

The Low-Level Alert Time can range from 1 to 5 minutes

(default: 3). To configure the Low-Level Alert Time, see

ADVANCED PROGRAMMING instructions, page 20.

A4 – Missed Cycle Threshold

While operating in Cycle Mode, the Cycle Alarm Threshold configures the controller to set the number of consecutively missed Cycles allowed before activating an alarm.

The Cycle Alarm Threshold can range from 0-99 cycles

(default:0). To configure the Cycle Alarm Threshold, see

ADVANCED PROGRAMMING instructions, page 20.

A5 – Low-Level Power Cycle Retry

When set to ON, the Low-Level Auto Clear feature allows the controller to attempt to automatically clear a

Low-Level Alarm during the power cycle. This feature is only used when a controller has the power removed while in a Low-Level Alarm state.

The Low-Level Auto Clear is an OF (OFF) or On (ON) selection.

• OF (OFF) (default) – Upon power cycle, the controller will remain in its current Low-Level Alarm state.

• On (ON) – Upon power cycle, the controller will begin a lubrication cycle to determine if a Low-Level condition still exists.

See ADVANCED PROGRAMMING instructions, page

20.

A6 – Low-Level Alert Enable

The Low-Level Warning Enable feature configures the controller to trigger a Low-Level Alert prior to the escalation of an Alarm.

The Low-Level Warning Enable is an OF (OFF) or On

(ON) selection.

• OF (OFF) (default) – Low-Level conditions are immediately escalated to Alarm status.

• On (ON) – Low-Level conditions are first reported as an Alert for the duration of setting A3, at which point they escalate to an Alarm.

See ADVANCED PROGRAMMING instructions, page

20.

A7 – Cycle Count Enable

The Cycle Lubrication Enable feature configures the controller to use Cycle Counts to monitor the duration of a lubrication period and enables the M12 Cycle Indicator

Connector.

The Cycle Lubrication Enable is an OF (OFF) or On

(ON) selection.

• OF (OFF) (default) – The lubrication period will be monitored in minutes.

• On (ON) – The lubrication period is monitored in cycles. This requires the addition of a proximity switch. The number of cycles must also be config-

ured in SET UP mode (page 18).

See ADVANCED PROGRAMMING instructions, page

20.

22 3A6714B

Alerts and Alarms

Alerts and Alarms

The controller monitors and displays two types of events: Alerts and Alarms.

Alerts

Alerts do not cause the lubrication cycle to stop. These events are automatically cleared based upon the alert received.

An amber LED illuminates under ALARM on the display when an

Alert occurs. See

Alert and Alarm Scenarios on page 24 for a description of

Alerts that could occur.

Alarms

Alarms cause the lubrication cycle to stop. Alarms can trigger immediately or can be the result of an escalated

Alert. Alarms must be cleared immediately.

A red LED illuminates under ALARM on the display when an Alarm occurs. See the

Alert and Alarm Scenarios table on page 24 for a descrip-

tion of Alarms that could occur.

When an Alarm is triggered, any active lubrication cycle will be terminated. The display begins to count up to identify how long the Alarm condition has been present.

The counter begins in minutes, then changes to hours, with a limit of 99 hours.

See

ADVANCED PROGRAMMING , page 20 for addi-

tional information about configuring the controller for

Alerts and Alarms.

3A6714B 23

Alerts and Alarms

Alert and Alarm Scenarios

The following pages describe the most likely alerts and alarms:

Alarm Type

Low-Level

Display

Cycle

Over

Current

System

Fault

What it Indicates

There is a low-level of lubricant in the reservoir

Solution

Add lubricant to reservoir.

An alert will auto-clear.

An alarm must be reset by pressing and holding the

Cancel Button for 4 seconds.

The cycle was not completed in the amount of configured time.

Check for a plugged or broken line, or other component failure such as a divider valve.

An alert will auto-clear.

An alarm must be reset by pressing and holding the

Cancel Button for 4 seconds.

The measured motor current is above the maximum operating level.

Check to make sure that the system is operating correctly. A blocked line could create excessive motor current.

The motor turns off and a new lube cycle is not allowed to be initiated.

Examine the pump to verify it is rotating properly.

An alarm must be reset by pressing and holding the

Cancel Button for 4 seconds.

An internal fault has occurred.

Attempt a power cycle of the device.

The controller may not be recoverable from this state.

If the alarm does not clear, contact Graco

Customer Service.

24 3A6714B

Troubleshooting

Troubleshooting

1.

Follow Pressure Relief Procedure , page 12,

before checking or repairing.

Problem Cause Solution

Unit does not power on.

Lubricant leaks past the seal located on the bottom of the reservoir.

Incorrect/loose wiring

Tripped external fuse due to internal component failure.

Tripped external fuse from using grease with an inadequate temperature rating in a cold environment.

Seal was not installed correctly.

Reservoir is being pressurized during filling.

Motor failure.

Refer to

Installation instructions, page 6.

Contact Graco Customer Service.

Replace lubricant with a lubricant rated for environmental conditions and application.

Replace fuse.

Replace seal.

Ensure that the vent tube is not plugged.

If the problem persists, contact

Graco Customer Service or your local Graco distributor for assistance.

Replace the motor.

The external controller is functioning, but the unit is not pumping during the ON cycle.

The follower plate is not moving downward.

After wiring and installing the equipment, the pump is not working.

Air is trapped in the reservoir between the follower plate and the lubricant.

The pump is wired incorrectly.

Add grease following the

Grease

Load

instructions, page 13.

Purge any air from the reservoir.

Rewire the pump following Wiring and Installation Diagrams , page 9.

3A6714B 25

Maintenance

Maintenance

Frequency

Daily and at Refill

Component

Fill Fittings

Daily

Monthly

Pump Unit and Reservoir

External Wiring Harness

Required Maintenance

Keep all of the fittings clean using a clean dry cloth.

Dirt and/or debris can damage the pump and/or the lubrication system.

Keep pump unit and reservoir clean using a clean dry cloth.

Verify external harnesses are secure.

26 3A6714B

Repair

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Reservoir Kits

Kit No.

26C943

26C945

26C944

26C946

Description

Kit Replacement, Reservoir, 1L

Kit Replacement, Reservoir, 0.5L

Kit Replacement, Reservoir, Follower

Plate, 1L

Kit Replacement, Reservoir, Follower

Plate, 0.5L

Pump Element Kits

Kit No.

26C947

26C948

Description

Standard G-Mini Pump Element;

Output: 3 cc/min.

Alternative G-Mini Pump Element;

Output: 1.5 cc/min.

Repair

3A6714B 27

Parts

Parts

1

1a

4a, 4b

45

46

44

43

42

19

10

3

41a, 41b, 41c

39

38

28

2

1b

3b

3a

5

6

12

11

19

1

20

23

24

28

22 2

50

25a, 25b

32a, 32b 3

33

34

1

Torque to 13 in-lb (1.5 N•m)

2

Torque to 65 in-lb (7.3 N•m)

3

Torque to 23 in-lb (2.6 N•m)

19 1

3A6714B

Parts

6

10

11

12

19

Part No./Description

Ref.

Part

1a

1b

2

3a

3b

4a

4b

5

20

22

Description Qty.

Reservoir, 1.0 Liter, included in kits 26C943, 26C944 -

Model 25R800, 25R801, 25R802,

25R803, 25R804, 25R805,

25R806

Reservoir, 0.5 Liter, included in kits 26C945, 26C946 -

Model 25R807, 25R808, 25R809,

25R810

Label, max fill, included in kits

26C943, 26C944 -

Model 25R800, 25R801, 25R802,

25R803, 25R804, 25R805,

25R806

Label, branding, 1L, included in kits 26C943, 26C944 -

Model 25R800, 25R801, 25R802,

25R803, 25R804, 25R805,

25R806

Label, branding, 0.5 Liter, included in kits 26C945, 26C946 -

Model 25R807, 25R808, 25R809,

25R810

Spring, compr., 1.0 Liter

Reservoir, included in kit 26C944 -

Model 25R800, 25R801, 25R802,

25R803, 25R804, 25R805,

25R806

Spring, compr., 0.5 Liter

Reservoir, included in kit 26C946 -

Model 25R807, 25R808, 25R809,

25R810

Wiper, follow, included in kits

26C944, 26C946

Plate, follow, included in kits

26C944, 26C946

Nut, M8*1.25 LH

Blade, agitator

Washer, paddle, ID8/OD16

Screw, ST4.2

Seal, Reservoir, included in kits

26C943, 26C944, 26C945,

26C946

Pump element, assy, included in kits 26C947, 26C948 -

Model 25R805

Pump element, assy, included in kits 26C947, 26C948 -

Model 25R800, 25R801, 25R802,

25R803, 25R804, 25R806,

25R807, 25R808, 25R809,

25R810

1

1

1

1

1

1

1

1

1

1

1

3

10

1

2

1

3A6714B

Ref.

Part Description Qty.

28

32a

32b

33

34

38

39

23

24

25a

25b

41a

41b

41c

100721 Plug, 1/4 npt, HEX socket

123741 Nipple

Label, overlay, BLK -

Model 25R800, 25R802, 25R807,

25R809

Label, overlay, controller version -

Model 25R801, 25R803, 25R804,

25R805, 25R806, 25R808,

25R810

1

1

111139

PCB, Board, assy, Compact Pump 1

Motor, 24VDC 1

Motor, 12VDC 1

Seal, bottom cover 1

Cover, bottom

O-ring

1

4

Label, Series

Harness, Ctrl -platform, CPC to

1

PCB -

Model 25R801, 25R803, 25R808,

25R810

1

Harness, Ctrl - platform, CPC to

PCB, PTC heater-

Model 25R801, 25R803, 25R808,

25R810

Harness, Ctrl - platform, CPC to

PCB, PTC heater -

Model 25R804, 25R805, 25R806

1

1

2

1

42

43

Washer, lock, M12 -

Model 25R801, 25R803, 25R805,

25R806, 25R808, 25R810

Harness, Ctrl - platform, M12 to

PCB -

Model 25R801, 25R803, 25R805,

25R806, 25R808, 25R810

44

Plug, M12 -

Model 25R801, 25R803, 25R805,

25R806, 25R808, 25R810

Base, Pump 45

46

Plug, M20 -

Model 25R800, 25R801, 25R802,

25R803, 25R804, 25R806,

25R807, 25R808, 25R809,

25R810

50  16A579 Label, Warning

1

1

1

1

1

1

 Replacement safety labels, tags, and cards are available at no cost.

29

Dimensions

Dimensions

Model

0.5L

1L

Height - A

Inches

10.9

12.2

cm

27.7

31.0

Inches

6.97

6.97

Width - B cm

17.7

17.7

Inches

6.57

6.57

Depth - C cm

16.7

16.7

30 3A6714B

Pump Mount CSP Valve Bracket Mount

Dimensions

Universal Bracket Mount

3A6714B 31

Technical Specifications

Technical Specifications

G-Mini Pump

Maximum fluid working pressure

Power

12 VDC

24 VDC

Inputs - Proximity Switch

Pump Voltage: 12 VDC

Pump Voltage: 24 VDC

Outputs - Low Level

Contact Rating

Switch Rating

Switching Current

Carry Current

Outputs - Tri-color Button

Pump Voltage: 12 VDC

Pump Voltage: 24 VDC

Pump Output

Pump Outlet

Reservoir Size

US

4061 psi

22 mA at 24 VDC

Metric

9-16 VDC; 9.5 A current, 114 W, inrush/locked rotor 12 A

18-32 VDC; 6.5 A current, 156 W, inrush/locked rotor 7.5 A

PNP Style Switch and Cable Only

11 mA at 12 VDC

28 MPa, 280 bar

100 W maximum

200 VDC maximum

0.5 A maximum

1.2 A maximum

11 mA at 12 VDC

22 mA at 24 VDC

3.0 cc minute at room temperature with 4061 psi (28 MPa,

280 bar) back pressure

1/4 in. NPT female

0.5 L

1.0 L

IP69K IP Rating

Working Temperature*

Non-Heater Model

Heater Model

Weight

Wetted parts

Sound data

5°F to 158°F

-40°F to 158°F

-15°C to 70°C

-40°C to 70°C

8.8 lb 4 kg carbon steel, alloy steel, stainless steel, nitrile rubber

(buna-N), bronze, nickel plated alnico, chemically lubricated acetal, aluminum, PTFE, amorphous polyamide, nylon 6/6

(PA)

<60dB

*Achieving the minimum working temperature is contingent on using a temperature compliant grease in an appropriately designed system.

32 3A6714B

Technical Specifications

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.

3A6714B 33

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

.

For patent information, see www.graco.com/patents .

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 3A6714

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2020, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision B , March 2020

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