Graco 3A0414N - G3 Automatic Lubrication Pump Instructions

Instructions
G3 Automatic
Lubrication Pump
3A0414N
EN
For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For
Professional Use Only.
Not approved for use in European explosive atmosphere locations.
Part Nos., page 3
5100 psi (35.1 MPa, 351.6 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
TI14705
Table of Contents
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3
2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 6
16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Understanding the Model Number . . . . . . . . . . . 7
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 11
Choosing an Installation Location . . . . . . . . . . . 12
System Configuration and Wiring . . . . . . . . . . . 13
Cable Wiring Diagrams . . . . . . . . . . . . . . . . . . . 23
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connecting to Auxiliary Fittings . . . . . . . . . . . . . 28
Setting Pump Outlet Volume . . . . . . . . . . . . . . . 29
Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 30
Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
No Controller Operation . . . . . . . . . . . . . . . . . . . . 32
Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 34
Pro Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control Panel Overview (FIG. 13) . . . . . . . . . . . 35
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Max Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control Panel Overview (FIG. 14) . . . . . . . . . . . 39
Programming the Max Model . . . . . . . . . . . . . . 40
PUMP OFF / REST Setup . . . . . . . . . . . . . . . . 44
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . 80
Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 81
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Mounting Pattern
(For correct mounting configuration, choose
either Option 1 or Option 2). . . . . . . . . . . . . 84
Wall Mounting Template . . . . . . . . . . . . . . . . . . 85
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 86
Graco Information . . . . . . . . . . . . . . . . . . . . . . . 86
DMS™ Models Only . . . . . . . . . . . . . . . . . . . . . 46
Storing Pump Program Settings to the Flash Drive
47
Uploading Pump Program Settings to the Pump 47
Operation / Data Log . . . . . . . . . . . . . . . . . . . . . . . 48
System Event Log . . . . . . . . . . . . . . . . . . . . . . . 48
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Functional Summary . . . . . . . . . . . . . . . . . . . . . 51
Technical Summary . . . . . . . . . . . . . . . . . . . . . . 53
Advanced Programming . . . . . . . . . . . . . . . . . . . . 54
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Max Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 65
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2
3A0414N
Part / Model Numbers
Part / Model Numbers
The Part Number is a six-digit unique number that is only used to order the G3 Pump. Directly related to this six digit
Part Number is the configured Graco Model Number. This configured 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 7. The tables below shows the relationship between each Part Number and its related Model
Number.
2 Liter Models
No Control Models
Max Models
Part
Numbers.
Model Number
96G000
96G001
96G002
96G003
96G005
96G006
96G007
96G008
96G050
96G059
G3-G-12NC-2L0000-00C00000
G3-G-24NC-2L0000-00C00000
G3-G-ACNC-2L0000-0D000000
G3-G-12NC-2L0A00-L0C00000
G3-G-24NC-2L0A00-L0C00000
G3-G-24NC-2FA00-L0C00000
G3-G-ACNC-2L0A00-LD000000
G3-G-ACNC-2LFA00-LD00000
G3-A-24NC-2L0A00-L0C00000
G3-A-ACNC-2L0A00-LD000000
Pro Models
Part
Numbers
Model Numbers
96G011
96G012
96G013
96G014
96G027
96G028
96G029
96G033
96G034
96G070
96G079
G3-G-24PR-2L0L00-R0C00000
G3-G-24PR-2LFL00-R0C00000
G3-G-ACPR-2L0L00-0D000000
G3-G-ACPR-2LFL00-0D000000
G3-G-12PR-2L0000-00C00000
G3-G-24PR-2L0000-00C00000
G3-G-ACPR-2L0000-0D000000
G3-G-12PR-2L0L05-00C00000
G3-G-24PR-2L0L05-00C00000
G3-A-24PR-2L0L00-R0C00000
G3-A-ACPR-2L0L00-0D000000
3A0414N
Part
Numbers
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
96G178
G3-G-ACMX-2L0L00-UDMVA1R2
G3-G-ACMX-2LFL00-UDMVA1R2
G3-G-24MX-2L0L00-0D00A100
3
Part / Model Numbers
4 Liter Models
No Control Models
Part
Numbers.
Model Number
96G038
96G040
96G042
96G044
96G048
96G051
96G053
96G055
96G060
96G062
G3-G-12NC-4L0000-00C00000
G3-G-24NC-4L0000-00C00000
G3-G-ACNC-4L0000-0D000000
G3-G-12NC-4L0A00-L0C00000
G3-G-24NC-4L0A00-L0C00000
G3-A-24NC-4L0A00-L0C00000
G3-G-24NC-4LFA00-L0C00000
G3-G-ACNC-4L0A00-LD000000
G3-A-ACNC-4L0A00-LD000000
G3-G-ACNC-4LFA00-LD000000
Pro Models
4
Part
Numbers
Model Numbers
96G068
96G071
96G073
96G075
96G080
96G082
96G135
96G137
96G139
96G147
96G149
G3-G-24PR-4L0L00-R0C00000
G3-A-24PR-4L0L00-R0C00000
G3-G-24PR-4LFL00-R0C00000
G3-G-ACPR-4L0L00-0D000000
G3-A-ACPR-4L0L00-0D000000
G3-G-ACPR-4LFL00-0D000000
G3-G-12PR-4L0000-00C00000
G3-G-24PR-4L0000-00C00000
G3-G-ACPR-4L0000-0D000000
G3-G-12PR-4L0L05-00C00000
G3-G-24PR-4L0L05-00C00000
Max Models
Part
Numbers
Model Numbers
96G088
G3-G-24MX-4L0L00-10CV00R0
96G090
G3-G-24MX-4LFL00-10CV00R0
96G092
G3-G-ACMX-4L0L00-1D0V0000
96G094
G3-G-ACMX-4LFL00-1D0V0000
96G096
96G099
G3-G-12MX-4L0L00-1DMVA2R3
G3-G-12MX-4L0L00-UDMVA1R2
96G103
96G108
96G111
G3-G-24MX-4L0L00-1DMVA2R3
G3-A-24MX-4L0L00-1DMVA2R3
G3-G-24MX-4L0L00-UDMVA1R2
96G113
G3-G-24MX-4LFL00-1DMVA2R3
96G116
G3-G-24MX-4LFL00-UDMVA1R2
96G118
G3-G-ACMX-4L0L00-1DMVA2R3
96G123
G3-A-ACMX-4L0L00-1DMVA2R3
96G126
G3-G-ACMX-4L0L00-UDMVA1R2
96G128
G3-G-ACMX-4LFL00-1DMVA2R3
96G133
G3-G-ACMX-4LFL00-UDMVA1R2
96G141
G3-G-12MX-4L0L00-10C00000
96G143
G3-G-24MX-4L0L00-10C00000
96G145
G3-G-ACMX-4L0L00-1D000000
96G151
G3-G-12MX-4L0L05-10CV0000
96G153
G3-G-12MX-4L0L05-U0CV0100
96G155
G3-G-24MX-4L0L05-10CV0000
96G157
G3-G-24MX-4L0L05-U0CV0100
96G159
G3-G-12MX-4L0L05-00C0010M
96G160
G3-G-24MX-4L0L05-00C0010M
96G161
G3-G-12MX-4L0L05-U0C0010M
96G162
G3-G-24MX-4L0L05-U0C0010M
3A0414N
Part / Model Numbers
8 Liter Models
No Control Models
Max Models
Part
Numbers.
Model Number
Part
Numbers
Model Numbers
96G039
96G041
G3-G-12NC-8L0000-00C00000
G3-G-24NC-8L0000-00C00000
96G089
G3-G-24MX-8L0L00-10CV00R0
96G093
G3-G-ACMX-8L0L00-1D0V0000
96G043
G3-G-ACNC-8L0000-0D000000
96G097
G3-G-12MX-8L0L00-1DMVA2R3
96G045
G3-G-12NC-8L0A00-L0C00000
96G100
G3-G-12MX-8L0L00-UDMVA1R2
96G049
G3-G-24NC-8L0A00-L0C00000
96G104
G3-G-24MX-8L0L00-1DMVA2R3
96G052
G3-A-24NC-8L0A00-L0C00000
96G056
96G061
G3-G-ACNC-8L0A00-LD000000
G3-A-ACNC-8L0A00-LD000000
96G109
96G112
G3-G-24MX-8L0L00-UDMVA1R2
96G119
G3-G-ACMX-8L0L00-1DMVA2R3
96G124
G3-A-ACMX-8L0L00-1DMVA2R3
96G127
G3-G-ACMX-8L0L00-UDMVA1R2
96G142
G3-G-12MX-8L0L00-10C00000
96G144
G3-G-24MX-8L0L00-10C00000
96G146
G3-G-ACMX-8L0L00-1D000000
96G152
G3-G-12MX-8L0L05-10CV0000
96G154
G3-G-12MX-8L0L05-U0CV0100
96G156
G3-G-24MX-8L0L05-10CV0000
96G158
G3-G-24MX-8L0L05-U0CV0100
96G177
G3-G-24MX-8L0L05-00C0010M
Pro Models
Part
Numbers
Model Numbers
96G069
96G072
96G076
96G081
96G136
96G138
96G140
96G148
96G150
G3-G-24PR-8L0L00-R0C00000
G3-A-24PR-8L0L00-R0C00000
G3-G-ACPR-8L0L00-0D000000
G3-A-ACPR-8L0L00-0D000000
G3-G-12PR-8L0000-00C00000
G3-G-24PR-8L0000-00C00000
G3-G-ACPR-8L0000-0D000000
G3-G-12PR-8L0L05-00C00000
G3-G-24PR-8L0L05-00C00000
3A0414N
G3-A-24MX-8L0L00-1DMVA2R3
5
Part / Model Numbers
12 Liter Models
16 Liter Models
No Control Models
No Control Models
Part
Numbers.
Model Number
Part
Numbers.
Model Number
96G057
G3-G-ACNC-120A00-LD000000
96G058
G3-G-ACNC-160A00-LD000000
Pro Models
Pro Models
Part
Numbers
Model Numbers
Part
Numbers
Model Numbers
96G077
96G163
G3-G-ACPR-120L00-0D000000
G3-G-24PR-120L05-00C00000
96G078
96G167
G3-G-ACPR-160L00-0D000000
G3-G-24PR-160L05-00C00000
Max Models
6
Max Models
Part
Numbers
Model Numbers
96G105
96G120
96G164
96G165
G3-G-24MX-120L00-1DMVA2R3
G3-G-ACMX-120L00-1DMVA2R3
G3-G-24MX-120L05-10CV00000
G3-G-24MX-120L05-U0CV0100
Part
Numbers
Model Numbers
96G106
G3-G-24MX-160L00-1DMVA2R3
96G121
G3-G-ACMX-160L00-1DMVA2R3
96G166
G3-G-ACMX-160L00-1D0V0000
96G168
G3-G-24MX-160L05-10CV0000
96G169
G3-G-24MX-160L05-U0CV0100
3A0414N
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
a
Code Sample:
a
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
•
•
•
12 = 12 Volts DC
24 = 24 Volts DC
AC = 100 - 240 Volts AC
e
f
f
-
g
h
i
j
k m n
p
Code e: Low Level Option
•
•
•
L = Low Level with Controller
A = External Low Level
0 = No Low Level monitoring
00 = No Options
05 = 5 Pin CPC power cable
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.
NC = No Controller
PR = Pro (Timer) Control
MX = Max (Cycle) Control
•
•
•
•
•
•
•
•
•
2L = 2 Liters
4L = 4 Liters
8L = 8 Liters
12 = 12 Liters
16 = 16 Liters
Code d: Follower Plate Installed
•
•
d
•
•
Code cc: Reservoir Capacity (Liters)
•
•
•
•
•
c
Code ff: Options
Code bb: Operation Control
•
•
•
c
F = Follower Plate Installed
0 = No Follower Plate
C = CPC
D = DIN
1, 2, 3 = Sensor Number
R = Remote Manual Run
M = Machine Count
A = Alarm Output
L = Low Level
V = Vent Valve
0 = Not populated
DMSTM Models
k
m
h
g
i
j
All G3 Models
n
p
FIG. 1
3A0414N
7
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 symbol refers to procedure-specific risk. When
these symbols appear in the body of this manual, refer back to these warnings. Additional, product-specific warnings
may be found throughout the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local 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.
•
Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
•
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•
Do not alter or modify equipment.
•
Use equipment only for its intended purpose. Call your distributor for information.
•
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•
Do not kink or over bend hoses or use hoses to pull equipment.
•
Keep children and animals away from work area.
•
Comply with all applicable safety regulations.
SKIN INJECTION HAZARD
High-pressure fluid from dispense 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 dispense 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 Pressure Relief Procedure in this manual, when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
•
8
Check hoses and couplings daily. Replace worn or damaged parts immediately.
3A0414N
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 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 MSDSs and recommendations.
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
3A0414N
•
Protective eyewear, and hearing protection.
•
Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
9
Installation
Installation
Grounding
The equipment must be grounded. Grounding reduces the risk of electric shock by providing an escape wire for the
electrical current in the event of malfunction or breakdown. This product is equipped with a cord having an equipment
grounding conductor. The wire with insulation having an outer surface that is green with or without yellow stripes is
the grounding wire.
Component Identification
N
L
A
M
Oil Models
DMSTM Models
Grease Models
C
Grease Models with Follower
Plate (2 liter models only)
P
E
D
I
H
F
K
96GXXX
G3-G-24NC-2L0A00-L0C00000
J
B
FIG. 2:
Key:
A
B
C
D
E
F
G
H
10
Reservoir
Adjustable Pump Element (1 included. Can accommodate
3 total)
Pressure Relief Valve (Not included / required for each
outlet - Available from Graco. See Parts, page 78.)
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. 4, page 29)
Fuse (DC models only - Not included, not shown.
Available from Graco. See Parts, page 78.)
Control Panel (Pro and Max models only)
I
J
K
L
M
N
P
Power / Sensor Panel (both sides; only one side shown)
Part Number / Model Number example only shown, (see
pages 3 and 7, Understanding the Model Number, for
details)
Power Cord (DIN shown)
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)
3A0414N
Installation
Typical Installation
Divider Installations
B
D
E
A
F
C
Injector Installations
G
E
F
B
H
D
A
C
A
B
C
D
Connected to fuse / power
Pressure relief valve (Not included for divider installations/
required for each outlet - user supplied. See Parts, page
78)
- Cycle indicator sensor cable (Divider Installations)
- Pressure switch cable (Injector Installations)
- Series progressive divider valves (Divider Installations)
- Injectors (Injector Installations)
3A0414N
E
F
G
H
To lube points
- Proximity Switch (Divider Installations)
- Pressure switch (Injector Installations)
Vent valve (Not included / available from Graco. See
Parts, page 78.)
Return to reservoir
11
Installation
Choosing an Installation Location
AUTOMATIC SYSTEM ACTIVATION HAZARD
Unexpected activation of the system could result in serious injury, including skin injection and amputation.
This device has an automatic timer that activates the pump lubrication system when power is connected or when exiting the programming function. Before you install or remove the lubrication pump from the system, disconnect and isolate all power supplies and relieve all pressure.
•
•
Select a location that will adequately support
the weight of the G3 Pump and lubricant, as
well as all plumbing and electrical connections.
12
Always mount the G3 upright.
•
If the G3 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.
Refer to your model number to confirm if a follower plate was installed on your pump. See
page 7, 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.
•
Some installations may require an additional
reservoir support bracket. Consult your Graco
distributor for assistance with this installation.
Refer to the two mounting hole layouts provided
in the Mounting Pattern section of this manual,
page 84.
NOTE: The two mounting hole layouts provided
in the Technical Data section show the only correct installation patterns to use for mounting the
G3. No other installation configurations should
be used.
•
•
Use designated mounting holes and provided
configurations only.
3A0414N
Installation
System Configuration and Wiring
Fuses
.
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.
If the product is permanently connected:
•
it must be installed by a qualified electrician or serviceman.
•
it must be connected to a grounded, permanent wiring system.
NOTICE
Fuses (user supplied) are required on all DC models. To avoid equipment damage:
•
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 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.
3A0414N
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.
Standard Remote
Illumination
(via 5 wire CPC power
cable - Kit 571049)
Alarm Output
Unit in OFF Mode
Unit in ON Mode
Deactivated (off)
Deactivated (off)
Off
On
Toggles On and Off once
Activated (on)
per second
Toggles On and Off Toggles On and Off once
once per second
per second
Warning Condition
Fault Condition
Fault Condition
Toggles On and Off
(Advanced Programming
once per second
Setting A7 OFF)
Fault Condition
(Advanced Programming Activated (on)
Setting A7 ON)
Tri-Color Remote
Illumination
(via illuminated manual run
input)
Off
Green
Yellow
Red
Toggles On and Off once
per second
Red
Toggles On and Off once
per second
Red
Alarm Relay Response
Output Tied to Common
No Faults or
Warnings
N.O.
N.C.
N.O.
Warning
N.C.
Fault
(Advanced
Programming A7
OFF)
Fault
(Advanced
Programming
Setting A7 ON)
14
N.O.
N.C.
1 second
N.O.
N.C.
3A0414N
Installation
Wiring and Installation Diagrams
The following Table identifies the wiring and installation diagrams provided in this manual. Additional wiring diagrams
for power cords and cables (described on the parts list, page 72) start on page 81.
Diagram
Page #
Power DIN AC
16
Power DIN DC
17
Power CPC DC
18
Inputs
19
Vent Valve Outputs
20
Alarm Outputs
21
Low Level Outputs
22
Illuminated Manual Run Input
3A0414N
Symbol
Kits: 571030, 571031,
571032, 571033
15
Installation
Power DIN AC
Connector on Housing
Pin-out (AC)
(2)
1 LINE
(3)
Black
2 NEUTRAL White
3 Not Used Not Used
(4)
4 GROUND Green/Yellow
(1)
Example Wiring Diagram
Black
White
1
2
3
Green/Yellow 4
16
3A0414N
Installation
Power DIN DC
NOTICE
Be sure when power is applied that stirring paddle
rotates clockwise (when viewed from the top). If it is
wired incorrectly paddle could rotate counter-clockwise
which will damage the pump’s internal components. If
this happens, stop the pump immediately and wire unit
correctly.
Connector on Housing
Pin-out (DC)
(1)
(3)
1 -VDC
Black
2 +VDC
White
3 Not Used Not Used
(4)
4 Not Used Green
(2)
Example Wiring Diagram
Ignition Switch
Fuse
1
2
3
4
12V-pump - 7.5A
24V pump - 4A
3A0414N
17
Installation
Power CPC DC
Connector on Housing
(2)
(1)
(3)
(7)
(6)
(4)
(5)
Pin-out
1 Not Used
Not Used
2
- VDC
Black
3 + VDC
White
4 Not Used
Not Used
5 Not Used
Not Used
6 Not Used
Not Used
7 Not Used
Green/Yellow
Example Wiring Diagram
1
2
Ignition Switch
Fuse
12V-pump - 7.5A
24V pump - 4A
18
3
4
5
6
7
3A0414N
Installation
Inputs (M12)
See Technical Data, page 81 for ratings.
Connector on Housing
Pin-out
(1)
(4)
1 SW +
2 Not Used
3 SW -
(2)
4 Signal
(3)
Example Wiring Diagram
Dry Contacts
1
2
3
4
Sink (NPN) 2 or 3 wire
1
2
3
4
3A0414N
Source (PNP) 2 or 3 wire
1
2
3
4
19
Installation
Vent Valve Outputs
See Technical Data, page 81 for ratings.
Connector on Housing
Pin-out
(3)
1 Not Used
2 Relief+
3 Relief (2)
(1)
Example Wiring Diagram
1
2
3
20
3A0414N
Installation
Alarm Outputs
DC example shown. See Technical Data, page 81 for ratings.
Connector on Housing
Pin-out
(1)
1 N.O.
(3)
2 N.C.
3 COM
4 Not Used
(4)
(2)
Example Wiring Diagram
1 A Fuse
G3
Alarm +9-30V
1 Amp Max
1
2
3
4
Switch closes on alarm
(shown in non-alarm position)
3A0414N
21
Installation
Low Level Outputs
See Low Level Output Option, page 32 for functional description. See Technical Data, page 81 for ratings.
Connector on Housing
Pin-out
(4)
(3)
1 Not Used
2 Not Used
(1)
3 LL N.O.
4 LL COM
(2)
Example Wiring Diagram
1
2
G3
3
4
22
3A0414N
Installation
Cable Wiring Diagrams
Part No. 126217: 3-Wire, 15 ft (4.5m)
Connector on Housing
(2)
(1)
(3)
(7)
(6)
(4)
(5)
Pin-out
1 Not Used
Not Used
2
- VDC
Black
3 + VDC
White
4 Not Used
Not Used
5 Not Used
Not Used
6 Not Used
Not Used
7 Not Used
Green/Yellow
Example Wiring Diagram
1
2
Ignition Switch
Fuse
12V-pump - 7.5A
24V pump - 4A
3A0414N
3
4
5
6
7
23
Installation
Part No.
123750: 5 Wire, 15 ft (4.5 m)
126219: 5 Wire, 20 ft (6.1 m)
126083: 5 Wire, 30 ft (91. m)
Connector on Housing
Pin-out
PIN PIN Name Wire Color
(2)
1 Not Used N/A
(1)
2
(3)
(4)
- VDC
Black
(7)
3 + VDC
Red
4 LIGHT
White
5 MANUAL Orange
(6)
6 Not Used N/A
(5)
7 Not Used Green w/ Yellow
Example Wiring Diagram
Fuse
12V-pump - 7.5A
24V pump - 4A
L
1
Black
White
4
5
ng
O
ra
3
e
Red
2
6
7
Green w/ Yellow
(Not Used)
24
3A0414N
Installation
Part No. 123358: DIN
Connector on Housing
Pin-out (AC)
(2)
1 LINE
(3)
Black
2 NEUTRAL White
3 Not Used Not Used
(4)
4 GROUND Green/Yellow
(1)
Example Wiring Diagram
Black
White
1
2
3
Green/Yellow 4
3A0414N
25
Installation
Part No. 124333: Cable Pin Out (M12)
Part No. 124300: Field Wireable Pin Out
(M12)
Wire Colors
Item No.
Color
Wire Colors
1
2
3
4
Brown
White
Blue
Black
Item No.
1
2
3
4
Color
Brown
White
Blue
Black
26
3A0414N
Installation
Part No. 124594: 4 Pin Eurofast Field
Wireable Connector
Part No. 124595: 5 Pin Eurofast Field
Wireable Connector
3A0414N
27
Setup
Setup
Connecting to Auxiliary Fittings
Pressure Relief
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.
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. 3 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
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.
•
FIG. 3
•
Only use a pressure relief valve that is rated for no
more than the working pressure of the G3 pump it is
installed on. 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 78.
28
3A0414N
Setup
Setting Pump Outlet Volume
3. Tighten pump element fitting. Torque fitting to 50 in.
lbs (5.6 N•m).
NOTE:
•
Before making any adjustments to pump volume,
Relieve Pressure following procedure on page 28.
•
Only use Graco supplied spacers to control output
volume.
•
It may be necessary to repeat this outlet volume
setup procedure after the pump is operating to
re-adjust the volume of dispensed fluids.
FIG. 4
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.
Pump volume control is set using either no (0) spacers, 1 or 2 spacers (FIG. 4).
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.
3A0414N
29
Setup
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. 6).
•
Do not operate G3 without reservoir attached.
•
max fill line
FIG. 6
NOTICE
Always clean fitting (D) with a clean dry cloth
prior to filling reservoir. Dirt and/or debris can
damage pump and/or lubrication system.
4. Remove fill hose.
Models with a follower plate:
• Care must be used when filling the reservoir
using a pneumatic or electric transfer pump to
not pressurize and break the reservoir.
1. Connect fill hose to inlet fitting (FIG. 5).
2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from
forming in grease.
Models without a follower plate:
1. Connect fill hose to inlet fitting (FIG. 5).
For models using an external controller, start pump
operation per your controller specifications.
E
For Max and Pro models press the
manual run button.
3. Fill reservoir with grease until seal of
follower plate breaches the vent hole (FIG. 7) and
the majority of air is expelled from the reservoir.
D
FIG. 5
2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from
forming in grease.
vent hole
For models using an external controller, start pump
operation per your controller specifications.
For Max and Pro models press the
manual run button.
FIG. 7
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.
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
30
3A0414N
Setup
Changing Greases
When changing greases, always use compatible fluids
or greases.
Filling Oil Unit
•
Only use oil 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. 8).
•
Do not operate G3 without reservoir attached.
•
Only use oils with at least 40 cSt.
FIG. 9
2. Only run pump until air is no longer dispensed with
the lubricant coming out of element fitting (FIG. 10).
a
b
FIG. 8
1. Remove fill cap (a).
2. Pour oil into reservoir to fill line (b).
FIG. 10
3. Tighten pump element fitting using two wrenches
working in opposite directions (FIG. 9).
3. Replace fill cap. Hand tighten cap, securely.
Priming
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. 9).
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume
3A0414N
31
No Controller Operation
No Controller Operation
The G3 Pump can be controlled using an external, user
supplied, power source and controller.
Refer to the Typical Installation diagrams provided on
page 11 for correct location of the required pump ground
wire and fuses.
•
Some G3 pumps without controllers include a Low Level
Output Option. The low level signal is monitored across
PINS 3 and 4. For PIN 3 and 4 locations and wiring
information the Low Level Outputs diagram, page 22.
NOTE: A low level warning is triggered when the controller detects PINS 3 and 4 have momentarily closed.
NOTE:
•
Low Level Output Option
When using an external power source and 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.
Grease Pumps
When the grease level has reached a low warning level,
PINS 3 and 4 momentarily close (1 time per paddle revolution) sending the signal that the fluid has reached a
low level to the controller.
To ensure that a low level condition has been met, 3 or
more low level triggers must be detected within 1 minute
or less.
See FIG. 11 for an illustration of a typical Low Level Output response to low grease level.
Typical Low Level Output Response with Low Level Fluid in Grease Models
200 ms
Closed
Contact
Position
Open
3s
FIG. 11
32
3A0414N
No Controller Operation
Oil Pumps
When the oil level has reached a low warning level,
PINS 3 and 4 close, sending the signal to the controller
that the fluid has reached a low level.
To ensure that a low level condition has been met, the
low level trigger must be detected for 10 continuous seconds.
See FIG. 12 for an illustration of a typical Low Level Output response to low oil level.
Typical Low Level Output Response with Low Level Fluid in Oil Models
Closed
Contact
Position
Open
FIG. 12
3A0414N
33
Quick Setup Guide
Quick Setup Guide
Complete setup instructions for Pro Models begin on page 35 and Max Models begin on page 39.
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34
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3A0414N
Pro Model Setup
Pro Model Setup
Control Panel Overview (FIG. 13)
NOTE: Programming instructions begin on page 36.
DISPLAY
•
OFF TIME
A blinking LED under HH, MM, SS or ##
indicates 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.
•
•
•
•
•
•
•
•
HH
ON TIME
•
•
•
•
LED lights when ON Time
sequence is running.
Display shows time as MM:SS
(minutes and seconds).
i.e., 08:30 is 8 minutes: 30 seconds.
Times lubrication cycle.
MM
ON
MM : SS
SS
##
LED lights when OFF Time sequence is
running.
Value is entered in HH:MM.
Displays in HH:MM (hours and minutes)
when > 1 hour.
Displays in MM:SS (minutes and second)
when < 1 hour.
Times pump rest between cycles.
Counts down from set time to zero.
!
ALARM ICONS
LED next to icon lights when a
fault / warning event occurs during a run cycle. See page 65 for
a complete description of these
alarm scenarios.
OFF
HH : MM
Counts down from a set time to
zero.
LOCK ICON
•
•
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 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 ALARM MODE: pressing and
holding for 3 seconds clears
fault / warning and switches
cycle to OFF MODE.
UP and DOWN ARROW
•
•
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.
RIGHT DIRECTION ARROW /
MANUAL RUN / ENTER:
•
•
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. 13
3A0414N
35
Pro Model Setup
Instructions
Powering Units With Controllers
By default, units with controllers are set to
operate in a timed mode with 1 minute of
ON time and 8 hours of OFF time. The unit
should be powered up in OFF mode,
counting down from the 8 hours. 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 3 seconds to move to the OFF mode.
The Pro Model uses a timer to regulate how long a
pump cycle runs and the length of time the pump rests
between cycles.
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 Entering a
PIN Code to Access
Setup Mode for instructions on entering a value.
Entering a PIN Code to Access Setup Mode
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 program settings and therefore, an
option for adding PIN Code authorization is available.
The instructions for setting a PIN Code are provided in
the Advanced Programming section of this manual. See
page 55.
To enter the PIN Code:
1. Press both the UP and
DOWN ARROW buttons for 3
seconds.
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 access 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.
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.
ON Time
36
•
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).
3A0414N
Pro Model Setup
•
•
•
An LED flashes under
either MM when programming minutes
OR SS when programming seconds.
6. After pressing the ENTER button to set
the last SS field, all the programmed ON
Time information is saved.
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
exceed 30 minutes. If 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.
The G3 automatically switches to the OFF Time
SETUP MODE.
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.
•
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.
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
flashes and the LED lights under SS; indicating it is
ready to program the seconds fields.
OR
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.
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.
5. Repeat steps 1 - 4 to set the SS (seconds) fields.
3A0414N
37
Pro Model Setup
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.
Setting Prelube
1. After you set the OFF Time information and press
the ENTER button, the G3 automatically switches to
the Prelube setup.
Notice the LED next to the prelube
icon on the G3 display lights indicating you are now in the Prelube setup
mode.
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.
38
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.
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 the G3 automatically
switches to the RUN MODE.
3A0414N
Max Model Setup
Max Model Setup
Control Panel Overview (FIG. 14)
NOTE: Programming instructions begin on page 40.
OFF TIME/BACKUP TIME
DISPLAY
•
ON TIME/BACKUP TIME
•
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.
•
ALARM ICONS
LED next to icon lights when a
fault / warning event occurs during a run cycle. See page 65 for
a complete description of these
alarm scenarios.
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.
•
PIN ICON
•
MACHINE COUNT
•
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.
•
•
•
PRELUBE
LED next to icon lights indicating LED lights when Prelube
function is enabled.
LEFT DIRECTION ARROW /
RESET
•
•
•
In ADVANCED and SETUP
MODES, moves cursor in display one field to the left.
In RUN MODE: single press
clears warning.
In ALARM MODE: pressing and
holding for 3 seconds clears
fault / warning and switches
cycle to OFF MODE.
LED next to icon lights indicating PIN is required to
enter setup.
In SETUP MODE LED
lights when setting up the
PIN.
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. 14
3A0414N
39
Max Model Setup
Programming the Max Model
Powering Units With Controllers
By default, units with controllers are set to
operate in a timed mode with 1 minute of
ON time and 8 hours of OFF time. The unit
should be powered up in OFF mode,
counting down from the 8 hours. 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 3 seconds to move to the OFF mode.
The Pro Model uses a timer to regulate how long a
pump cycle runs and the length of time the pump rests
between cycles.
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.
40
Entering a PIN Code to Access Setup Mode
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 55.
To enter the PIN Code:
1. Press both the UP and
DOWN ARROW buttons for 3
seconds.
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.
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.
3A0414N
Max Model Setup
Setting the Real Time Clock
DMS
™
Equipped Models Only
2. Press the ENTER button to set the
month.
The 2-digit date displays indicating the G3 is now
ready to program the date.
NOTE: Set the real time clock prior to plugging the USB
flash drive into the pump.
Enter the Year:
Enter the 2-digit Date:
•
The year displays.
The first programmable character, the
decade, blinks indicating the device is
ready to program the
decade digit of the year.
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
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.
2. Press the ENTER button to set the
decade number. The curser 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.
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.
2. Press the ENTER button to accept
the selection. The cursor automatically moves to the second digit of
the date.
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.
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.
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.
Enter the Month:
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.
3A0414N
or
41
Max Model Setup
•
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).
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.
•
Only sensor inputs that are available on the unit can
be programmed.
2. Press the ENTER button to set the
number.
Cycle (C1, C2, C3) Setup
•
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.
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.
NOTE: Field cannot be left blank. If C / P2 and C /
P3 are not used, OFF must be entered instead.
Cycle controls the number of lube cycles (as monitored
by an external cycle monitor) completed before the
pump rests.
NOTE:
4. Press the ENTER button to set the
number.
•
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.
1. Use UP or DOWN arrow button to toggle display between
OFF / C1 / P1 on the display.
6. Repeat steps 1-4 to set the minutes (MM) fields.
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:
•
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,
•
42
OFF - A specific duration of time elapses.
You must program at least one cycle. Zero is not an
available option.
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
3A0414N
Max Model Setup
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.
NOTE: If C / P2 and C / P3 are not used, the default
OFF setting must be entered instead.
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 44.
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.
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 56.)
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.
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:
•
Pressure control is an ON / OFF selection only.
1. Use the UP or DOWN arrow
button to toggle between OFF
/ C1/ P1.
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.
3A0414N
43
Max Model Setup
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.
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.
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:
•
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.
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.
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.
Programming Backup Time
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.
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.
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).
44
3A0414N
Max Model Setup
4. Repeat 2 - 3 to set the remaining fields.
NOTE: After the Machine Count value is entered, the G3
can be programmed to backup the machine count input
with time.
•
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.
Backup Time Setup
If this time does not meet the application needs,
contact Graco Customer Support.
1. The OFF Time LED lights.
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.
OFF displays.
2. Press the UP or DOWN
ARROW button to change
OFF to ON on the display.
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.
3. Press the ENTER button to set the
selection.
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.
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).
•
An LED flashes under
either HH when programming hours OR
MM when programming minutes.
•
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.
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 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.
7. After selecting ON, refer to page 43.
NOTE: Backup time can be set in HH:MM for the
machine count input.
3A0414N
45
Max Model Setup
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.
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.
ON - The unit begins a pump cycle.
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.
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
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 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.
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).
2. The system automatically begins downloading data
to the USB drive.
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.
4. When download is finished, “done” is
displayed.
3. “data” is displayed while the system
is downloading files.
5. G3 pump restarts cycle in the OFF mode.
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.
46
6. Remove the USB flash drive.
3A0414N
Max Model Setup
Storing Pump Program Settings
to the Flash Drive
The pump program settings file is named:
GRACO/G3Config/g3config.bin. This file cannot be
modified. Modification of the file or file name may cause
it to be unusable.
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 restarts cycle in the OFF mode.
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 restarts cycle in the OFF mode.
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.
7. “data” is displayed while the unit is
downloading and storing the configuration on the USB drive.
8. When configuration is stored, “done”
is displayed.
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.
9. G3 pump restarts cycle in the OFF mode.
10. Remove the USB flash drive.
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 40).
12. In SETUP MODE, set the YEAR, MONTH, DATE
and TIME (see Setting the Real Time Clock, page
41).
9. G3 pump restarts cycle in the OFF mode.
13. After pressing the ENTER button to set
the TIME, press the RESET button to
exit the SETUP MODE.
10. Remove the USB flash drive.
Viewing the UNIT DMS ID Number
Uploading Pump Program
Settings to the Pump
1. Plug the USB flash drive into the USB port.
NOTE:
•
The USB flash drive must contain file
GRACO/G3Config/g3config.bin.
•
The G3 pump stops pumping as soon as the
USB flash drive is plugged into it.
3A0414N
1. In RUN mode, press and hold the
DOWN ARROW button.
2. The Unit DMS ID number displays. The
unit continues to normal operation while
the DMS ID is displayed.
3. Release the DOWN ARROW button after viewing
the DMS ID number.
47
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 47)
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/G3_{DMS_id}/{download date - YYYYmmDD}/EVENTLOG.CSV
Example: GRACO/G3_00025/20100911/EVENTLOG.CSV.
48
3A0414N
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
Venting Detected
In an injector system, the pump on cycle
has completed and the system is currently venting pressure through the vent
valve.
Prelube Initiated
The pump has entered a prelube delay
after powering up.
Prelube Completed
The pump has completed prelube delay
and will begin a pump on cycle.
Successful Pin
Code Entry
The pin code was successfully entered
and the user has entered setup mode.
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 Cancelled
A pump on cycle was cancelled by
pressing the cancel button on the front
panel and holding it for 3 seconds.
G3 Power On
The pump powered on.
G3 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
Machine Count
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.
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.
3A0414N
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/G3_{DMS_id}/{download date - YYYYmmDD}/ERRORLOG.CSV
Example: GRACO/G3_00025/20100911/ERRORLOG.CSV.
Sample Error Log
G3 Error Log
DMS ID Number: 00025 (see page 47)
Software Part Number:16F821
Software Version:0205
12/31/2015
23:04:00
Date
Time
12/31/2015 23:03:54
12/31/2015 23:03:42
12/31/2015 23:03:32
12/31/2015 23:03:22
12/31/2015 23:03:22
12/31/2015 23:03:19
12/31/2015 23:03:19
12/31/2015 23:02:20
12/31/2015 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
49
Operation / Data Log
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.
Cycle 1 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.
Cycle 2 Not Detected
Cycle 3 Not Detected
Pressure 1 Not
Detected
Pressure 2 Not
Detected
In an injector system the system has not received a signal
from the pressure switch in the
designated backup time.
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.
Pressure 3 Not
Detected
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
50
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.
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.
3A0414N
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 58).
•
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/G3_{DMS_id}/{download date - YYYYmmDD}/FUNCSUM.CSV
Example: GRACO/G3_00025/20100911/FUNCSUM.CSV
Sample Functional Summary
(see page 47)
3A0414N
51
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.
52
3A0414N
Operation / Data Log
Technical Summary
Example: GRACO/G3_00025/20100911/TECHSUM.CSV
The Technical Summary contains two types of data.
•
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.
Average Motor Current
The average motor current measured by the unit.
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.
Peak Motor Current
The peak motor current measured by the unit.
This is very similar to an odometer in your car.
Peak Internal Temperature
The peak internal temperature
seen by the unit.
Low Internal Temperature
The lowest internal temperature
seen by the unit.
The log file is stored as:
GRACO/G3_{DMS_id}/{download date - YYYYmmDD}/TECHSUM.CSV
Average Internal Temper- The average internal temperature
ature
seen by the unit.
Sample Technical Summary
G3 Technical Summary
DMS ID Number: 00025 (see page 47)
Software Part Number:16F821
Software Version: 0205
12/27/2010
9:50:51
Latest Values
Temp
Voltage
31C
23.877
Type
User
Factory
3A0414N
Average
Start Date Average Peak
Average Peak
Internal
Board
Motor
Motor
Board
Voltage
Current
Current
Temp
Voltage
12/21/2010
23.877
23.877
0.062
0.06230C
9/30/2010
22.804
23.877
1.091
0.36233C
Peak
Internal
Temp
35C
42C
Low
Internal
Temp
28C
-10C
53
Advanced Programming
Advanced Programming
There are 7 Advanced Programming options. The following Table Identifies each option and when it is used.
Advanced
Option
Model
Setting
Format/ Description
Why Use This?
A1
Max / Pro
Secures setup modes with
PIN
Prevents unauthorized users to adjusting
settings.
A2
Max / Pro
Lockout
Code
(Optional)
Low Level
Alarm Time
A3
Max Only
A4
Max Only
A5
Max Only
Vent Valve
Time
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.
• In an injector based system that does not
MM:SS (minutes:seconds)
use a sensor for feedback, determines
sets amount of time vent
the amount of time the system vents.
valve stays open after Pump
• Vent time can be modified.
ON Mode.
MM:SS (minutes:seconds)
sets amount of time
between Low Level Warning to Low Level Fault.
Default = 3 minutes
Default = 5 minutes
Establishes the number of times the unit
Alarm Retry Sets number of automatic
retries after a Cycle or Pres- automatically retries lubricating after a
cycle or pressure alarm to determine if a
sure Alarm.
temporary or false signal can be cleared.
Default = 0
Active
Uses alarm output to determine if a unit has
Changes alarm output
Alarm
behavior.
an alarm AND/OR loses power.
Default = OFF
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
Max /
DMS™
Equipped
Models Only
A7
Max Only
Functional
and Technical User
Summary
Reset
Constant
Alarm Output on Fault
Clears the Functional and
Technical User Summaries
Changes alarm output
behavior.
Used to manage power outage.
Allows user to track lube events from a specific point (reset), i.e. a month to month
evaluation.
This function changes the behavior of the
alarm output in a fault from either toggling
once every second or steady on.
Default = OFF
54
3A0414N
Advanced Programming
Entering Advanced Setup
A1 - Setting Up PIN Code
Press the UP ARROW button for 10 seconds.
A PIN Code can be programmed into the G3 to protect
the settings from inadvertently being changed by unauthorized users.
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.
The LED next to the LOCK ICON on the display lights, indicating you have entered the
PIN Mode.
1. 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.
2. Press the ENTER button to set the number. The cursor automatically moves to
the next number field.
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 - A5.
3. Repeat steps 1 and 2 for each PIN Code prompt
field.
4. The word OFF appears in the
display. Press the UP or
DOWN ARROW button to
change this to ON.
5. Press the ENTER button to set the PIN
Code and exit Advanced Setup.
2. Press the ENTER button to set the
selection.
3A0414N
55
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.
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.
Fault, and Low Level LED illuminate. (Max Model Display shown in illustration below).
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.
A-3 Vent Valve Time - (Max Model Only)
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. 15
Vent Valve time must be less than the programmed OFF
time (page 37). 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.
To set Vent Valve 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.
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.
•
Time is set as minutes and seconds (MM:SS) only.
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.
56
3A0414N
Advanced Programming
•
•
•
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.
A-4 Alarm Retry (Max Model Only)
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.
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.
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.
6. Repeat steps 1 - 4 to set the MM (seconds) fields.
7. After pressing the ENTER button to set
the last seconds field, all the programmed Time information is saved.
Unit exits Advanced Programming.
FIG. 16
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.
3. When the correct number displays,
press the ENTER button to set the number.
4. Repeat 2 - 3 to set the remaining fields.
Press the ENTER button to exit Advanced
Programming.
3A0414N
57
Advanced Programming
A-5 Active Alarm (Max Model Only)
Changes the alarm output behavior. Uses output to
determine if a fault has occurred.
Fault and ON LED’s illuminate.
FIG. 17
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.
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.
FIG. 18
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.
4. Press the RESET button. “Reset” displays.
The summary data is
cleared.
5. Press the RESET or
ENTER button to exit.
58
3A0414N
Advanced Programming
A-7- Constant Alarm Output on Fault
This function changes the behavior of the alarm output
in a fault from either toggling once every second
(default) or steady on.
Fault and Warning LEDs Illuminate
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
FIG. 19
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
3. Press the ENTER button to exit
Advanced Programming.
3A0414N
59
Run Mode
Run Mode
•
Time Control
After setup is complete, the G3 automatically begins to
run the OFF Time sequence (FIG. 20).
•
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. 21).
(Notice the ON Time LED is now illuminated on the
display.)
•
The G3 runs the programmed OFF sequence.
The example shown in FIG. 21 shows an ON Time of
8 minutes and 42 seconds before the lubrication
cycle ends.
(Notice the OFF Time LED on the display lights and
the OFF Time counts down on the display.)
HH
•
MM
SS
##
The example shown in FIG. 20 shows an OFF Time
of 1 hour and 32 minutes before the lubrication cycle
begins.
ON
MM : SS
HH
MM
ON
MM : SS
SS
##
!
OFF
HH : MM
!
OFF
HH : MM
FIG. 21
•
FIG. 20
60
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. 20).
This sequence repeats itself until the device is
reprogrammed or an alarm occurs.
3A0414N
Run Mode
Max Model
Pressure Control
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.
•
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 (FIG. 23 and FIG. 24).
•
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.
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 60).
The example shown in FIG. 23 shows sensor P1
with a pressure switch that has been triggered.
With cycle and/or pressure controls set, the lubrication
cycle (Pump ON) is ended by meeting all required cycle
and/or pressure settings.
FIG. 24 (page 62) shows sensor P2 with a pressure switch that has NOT been triggered.
Cycle Control
•
A set number of triggered counts in a cycle
based system (C1). Typically a proximity switch
connected to a divider valve.
•
The LED next to the appropriate sensor (C/P1,
C/P2, C/P3) illuminates.
•
The display indicates the sensor (C1, C2, C3)
and the remaining cycles for that sensor (FIG.
22).
HH
The example shown in FIG. 22 shows sensor C1
with 5 cycles remaining.
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
!
C
P2
C
C
P3
P
123
FIG. 23
C
P1
C
P2
C
C
P3
P
123
FIG. 22
3A0414N
61
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. 25 shows 14 minutes and 33 seconds left until the fault occurs.
•
C
P1
C
P2
C
C
P3
P
123
If all cycle and/or pressure requirements are
met the unit exits the lubrication cycle (Pump
ON) and enter the rest cycle (Pump OFF).
HH
FIG. 24
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
FIG. 25
62
3A0414N
Run Mode
Max Model
Backup Time
Rest Mode (Pump OFF) Controls
In Machine Count mode, if a Backup Time (maximum
rest time) has been set:
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.
•
The LED next to 1-2-3 illuminates (FIG. 27).
•
The display shows the amount of time remaining till a fault.
The example shown in FIG. 27 shows 4 hours
and 17 minutes remaining until a fault occurs.
•
With machine count set, the Rest Cycle (Pump OFF) is
ended when the machine count reaches zero (0000).
If the Machine Count requirements are met the
unit will exit the Rest Mode (Pump OFF) and
enter the Lubrication Mode (Pump ON).
HH
MM
SS
##
Machine Count
•
A set number of triggered counts.
•
The LED next to 1-2-3 illuminates (FIG. 26).
•
The display indicates the number of machine
counts remaining.
ON
OFF
MM : SS
HH : MM
The example shown in FIG. 26 shows the
remaining number of machine counts is 0045.
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
!
C
P2
C
C
P3
P
123
FIG. 27
OFF Time
C
P1
C
P2
C
C
P3
P
123
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 60).
FIG. 26
3A0414N
63
Run Mode
Additional Controls
Prelube Delay
Venting
The Prelube function has been selected. Prelube delay
is set to something other than 00:00:
In Max models a Vent Time can be set using the
Advanced Programming mode (page 56). This is typically done in a Pressure Based System (P1) to allow
injectors to reset.
•
Power to the unit cycles OFF then ON.
•
Unit immediately begins the Prelube Delay
count down until the lubrication cycle begins.
•
Unit vents for a set amount of time (not displayed).
•
The LED next to the clock in the OFF field is illuminated (FIG. 28).
•
The LED’s next to C/P1, C/P2, C/P3 flash while
unit is venting.
•
The Prelube LED lights (FIG. 28).
•
•
If Machine Count is set, the display will alternate
between machine counts remaining and backup
time (Max Model Rest Mode, page 63).
The display shows time remaining until lubrication cycle begins. The example shown in FIG. 28
shows 8 minutes and 14 seconds left until a
lubrication cycle begins.
•
If Machine Count has been set the LED next to
1-2-3 illuminates (FIG. 26, page 63).
•
If Machine Count has not been set the display
shows OFF Time (See Time Control, page 60).
•
If Machine Count has not been set the LED next
to the clock in the OFF field illuminates (See
Time Control, page 60).
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
Prelube / Prelube Delay
In all models a power OFF/ON cycle can be controlled
with the Prelube and Prelube Delay functions.
C
P1
C
P2
C
Prelube
C
P3
P
The Prelube function has been selected. Prelube delay
is set to 00:00:
•
Power to the unit cycles OFF then ON.
•
Unit immediately begins a lubrication cycle.
•
Pro Model - display shows ON Time (See Time
Control, page 60).
•
Max Model - display shows Cycle/Pressure/Backup Time (See Max Model Lubrication
Mode Controls, page 61).
123
FIG. 28
Manual Run Cycle
To run an extra (non-programmed) lubrication cycle, push the Manual Start button.
NOTE: Manual Run option is not available while unit is
in Vent Mode.
64
3A0414N
Alarms
Alarms
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
C
P2
C
C
P3
P
123
Low Level
Fault
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
C
P1
3A0414N
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 56.
65
Alarms
Cycle /
Pressure
Warning
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
!
C
P1
C
P2
C
C
P3
P
123
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 54).
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.
Cycle /
Pressure
Fault
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
C
P1
C
P2
C
C
P3
P
!
In pressure mode indicates that unit is over pressurized or a lubrication
cycle was not completed in
the user-defined amount of
time.
In cycle mode indicates
that a 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.
Press and
hold the
RESET button to clear
fault.
123
LED corresponding to the
affected sensor input
blinks.
Could be more than one
sensor alarm at the same
time.
66
3A0414N
Alarms
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
HH
MM
SS
##
ON
OFF
MM : SS
HH : MM
An internal fault has
occurred.
Contact Graco Customer
Service.
The measured motor current is above the recommended operating
maximum value. Continued
use at excessive motor currents could reduce life or
cause permanent damage.
Examine system to make
sure it is operating correctly. A blocked line could
create excessive motor
current
!
C
P1
Motor Current Warning
C
P2
C
C
P3
P
HH
123
MM
SS
##
ON
OFF
MM : SS
HH : MM
3A0414N
C
C
P3
P
Examine pump to ensure
that it is rotating properly.
If necessary, contact
Graco Customer Service.
C
P1
C
P2
!
123
67
Alarms
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 temperIf necessary contact
ature range could cause
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 69) for error numbers and fault descriptions.
C
P1
68
C
P2
C
C
P3
P
123
3A0414N
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 10.
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 30. 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
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 36 and 42.
In an Injector System without sensor Vent valve time needs to be configfeedback, unit does not vent properly ured
3A0414N
Add 1 stroke adjust spacer and
adjust lube cycle time to accommodate the difference in pump volume
per stroke.
Refer to Advanced Programming to
set ON Time, page 54.
69
Troubleshooting
Problem
Cause
Solution
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 47 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 47 for instructions.
USB Error 07
Bad pump program settings file
USB Error 13
Unplug the flash drive and
re-install.
• 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.
The pump programs settings file is
corrupt. Restore file to the flash drive.
See Storing Pump Program Settings
to the Flash Drive, page 47 for
instructions.
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.
70
3A0414N
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.
3A0414N
71
Parts
Parts
Ref
1
Part
Description
BASE, three pump housing
Qty
1
3
278142 COVER, bottom, with seal
1
4
115477 SCREW, mach, torx pan hd
9
13
O-RING, 258, included in Kit
124396 571042, 571043, 571044, 571045,
571069, 571179
O-RING, included in Kit 571069,
124510
571179, 571182, 571183
2
1
14
PLATE, ricer
1
15
BEARING, ball
1
16
PADDLE, stirring, 2 Liter models
without follower plate - models
96G000, 96G001, 96G002,
96G003, 96G005, 96G007,
96G009, 96G011, 96G013,
96G015, 96G017, 96G019,
96G021, 96G023,
96G025-96G037, 96G098,
96G110, 96G125, included in Kit
571044, 96G178
PADDLE, stirring, 4 Liter models
without follower plate - models
96G038, 96G040, 96G042,
96G044, 96G048, 96G055,
96G064, 96G066, 96G068,
96G075, 96G084, 96G088,
96G092, 96G096, 96G099,
96G103, 96G111, 96G118,
96G126, 96G135, 96G137,
96G139, 96G141, 96G143,
96G145, 96G147, 96G149,
96G151, 96G153, 96G155,
96G157, 96G159, 96G160,
96G161, 96G162
Ref
1
1
17
18
21
72
Part
Description
Qty
PADDLE, stirring, 8 Liter models
without follower plate - models
96G039, 96G041, 96G043,
96G045, 96G049, 96G056,
96G065, 96G069, 96G076,
96G085, 96G089, 96G093,
96G097, 96G100, 96G104,
96G112, 96G119, 96G127,
96G136, 96G138, 96G140,
96G142, 96G144, 96G146,
96G148, 96G150, 96G152,
96G154, 96G156, 96G158,
96G177
PADDLE, stirring, 12 Liter models
without follower plate - models
96G057, 96G077, 96G105,
96G120, 96G163-96G165
PADDLE, stirring, 16 Liter models
without follower plate - models
96G058, 96G078, 96G106,
96G121
PADDLE, stirring, 2 Liter models
with follower plate - models
96G004, 96G006, 96G008,
96G010, 96G012, 96G014,
96G016, 96G015, 96G018,
96G020, 96G022, 96G024,
96G026, 96G115, 96G132 included
in Kit 571045
PADDLE, stirring, 4Liter models
with follower plate - models
96G046, 96G053, 96G062,
96G073, 96G082, 96G086,
96G090, 96G094, 96G101,
96G113, 96G116, 96G128,
96G133
PUMP, element, included in Kit
571041
SPACER, stroke adjust, included in
16F368
Kit 571041
278145 PLUG, pump, 3/4-16
1
1
1
1
1
1
2
2
3A0414N
Parts
Ref
23
27
30
‡
Part
278136
123025
258760
‡ 258697
3A0414N
Description
PADDLE, low level, models
96G003-96G008, 96G015-96G026,
96G033-96G038, 96G044-96G046,
96G048, 96G049, 96G053,
96G055-96G058, 96G062,
96G064, 96G065, 96G068,
96G069, 96G073,
96G075-96G078, 96G082,
96G084-96G086, 96G088-96G090,
96G092-96G094, 96G096-96G101,
96G103-96G106, 96G110-96G113,
96G115, 96G116,
96G118-96G121, 96G125-96G128,
96G132, 96G133,
96G141-96G165, 96G177, 96G178
SCREW, M6, models
96G003-96G008, 96G015-96G026,
96G033-96G038, 96G044-96G046,
96G048, 96G049, 96G053,
96G055-96G058, 96G062,
96G064, 96G065, 96G068,
96G069, 96G073,
96G075-96G078, 96G082,
96G084-96G086, 96G088-96G090,
96G092-96G094, 96G096-96G101,
96G103-96G106, 96G110-96G113,
96G115, 96G116,
96G118-96G121, 96G125-96G128,
96G132, 96G133,
96G141-96G165, 96G177, 96G178
BOARD, circuit, Pro, models
96G009 - 96G014,
96G027-96G029, 96G033,
96G034, 96G064, 96G065,
96G066, 96G069-96G072,
96G075-96G082, 96G135-96G140,
96G147, 96G148, 96G150,
96G163
BOARD, circuit, Max, models
96G015-96G026, 96G030-96G032,
96G035-96G037, 96G084-96G086,
96G088-96G090, 96G092-96G094,
96G096-96G101, 96G103-96G113,
96G115, 96G116,
96G118-96G128, 96G132,
96G133, 96G141-96G146,
96G151-96G161, 96G164,
96G177, 96G178
Qty
Ref
Part
‡ 262463
1
31
119228
33
16A579
16C473
1
16A578
34
1
16A073
Description
BOARD, circuit, Max, DMS™
models 96G098-96G100,
96G110-96G112, 96G115,
96G116, 96G125-96G128,
96G132, 96G133, 96G153,
96G154,96G157, 96G158,
96G161, 96G162, 96G165
SCREW, machine, flat head, models 96G009-96G037,
96G064-96G066, 96G069-96G072,
96G075-96G082, 96G084-96G086,
96G088-96G090, 96G092-96G094,
96G096-96G101, 96G103-96G113,
96G115, 96G116,
96G118-96G128, 96G132,
96G133, 96G135-96G148,
96G150-96G165, 96G177, 96G178
LABEL, safety, included in Kit
571041
LABEL, controller blank, models
96G000-96G008, 96G038-96G046,
96G048-96G053, 96G055-96G062,
96G068, 96G073, 96G149
LABEL, overlay, models 96G009,
96G010-96G014, 96G027-96G029,
96G033, 96G034,
96G064-96G066, 96G069-96G072,
96G075-96G082, 96G135-96G140,
96G147, 96G148, 96G150,
96G163
LABEL, overlay, models
96G015-9G025, 96G030-96G032,
96G035-95G037, 96G084-96G086,
96G088-96G090,96G092-96G094,
96G096-96G101, 96G103-96G113,
96G115, 96G116,
96G118-96G128, 96G132,
96G133,96G141-96G146,
96G151-96G162, 96G164,
96G165, 96G177, 96G178
Qty
2
1
1
1
73
Parts
Ref
35
36
Part
Description
WIPER, stirring, models without follower plate - models 96G000,
96G001, 96G002, 96G003,
96G005, 96G007, 96G009,
96G011, 96G013, 96G015,
96G017, 96G019, 96G021,
96G023, 96G025,
96G027-96G045, 96G048,
96G049, 96G055-96G058,
96G064-96G066, 96G068,
96G069, 96G075-96G078,
96G084, 96G085, 96G088,
96G089, 96G092, 96G093,
96G096-96G100, 96G103-96G106,
96G110-96G112, 96G118-96G121,
96G125-96G127, 96G135-96G165,
96G177, 96G178, included in Kit
571044
WIPER, stirring, models with follower plate - models 96G004,
96G006, 96G008, 96G010,
96G012, 96G014, 96G016,
96G018, 96G020, 96G022,
96G024, 96G026, 96G046,
96G053, 96G062, 96G073,
96G082, 96G086, 96G090,
96G094, 96G101, 96G113,
96G115, 96G116, 96G128,
96G132, 96G133 included in Kit
571045
LABEL, brand
FITTING, zerk, grease, not included
on models 96G050-96G052,
37 123741 96G059-96G061, 96G070-96G072,
96G079, 96G080,
96G107-96G109, 96G122-96G124
RESERVOIR, 2 liter, grease,
96G000-96G031, 96G033-96G037,
96G098, 96G110, 96G115,
40a 24E984 96G125, 96G132-96G033-96G037,
96G098, 96G110, 96G115,
96G125, 96G132, 96G178,
included in Kit 571042, 571069
RESERVOIR, 2 liter, oil, 96G050,
96G059, 96G070, 96G079,
40b 16G021
96G107, 96G122, included in Kit
571179
Qty
1
Ref
Part
40a 24B702
40b 16G020
1
40a
1
1
40b
40a
1
40a
41
278139
1
16F472
74
Description
Qty
RESERVOIR, 4 liter, grease,
96G038, 96G040, 96G042,
96G044, 96G046, 96G048,
96G053, 96G055, 96G062,
96G064, 96G066, 96G068,
96G073, 96G075, 96G082,
96G084, 96G086, 96G088,
96G090, 96G092, 96G094,
96G096, 96G099, 96G101,
96G103, 96G111, 96G113,
96G116, 96G118, 96G126,
96G128, 96G133, 96G135,
96G137, 96G139, 96G141,
96G143, 96G145, 96G147,
96G149, 96G151, 96G153,
96G155, 96G157, 96G159,
96G160, 96G161, 96G162,
included in Kit 571183
RESERVOIR, 4 liter, oil, 96G051,
96G060, 96G071, 96G080,
96G108, 96G123
RESERVOIR, 8 liter, grease,
96G039, 96G041, 96G043,
96G045, 96G049, 96G056,
96G065, 96G069, 96G076,
96G085, 96G089, 96G093,
96G097, 96G100, 96G104,
96G112, 96G119, 96G127,
96G136, 96G138, 96G140,
96G142, 96G144, 96G146,
96G148, 96G150, 96G152,
96G154, 96G156, 96G158,
96G178
RESERVOIR, 8 liter, oil, 96G052,
96G061, 96G072, 96G081,
96G109, 96G124, included in Kit
571182
RESERVOIR, 12 liter, 96G057,
96G077, 96G105, 96G120,
96G163, 96G164, 96G165
RESERVOIR, 16 liter, 96G058,
96G078, 96G106, 96G121
SEAL, follower plate, 2 liter models
96G004, 96G006, 96G008,
96G010, 96G012, 96G014
SEAL, follower plate, 4 liter models
96G046, 96G053, 96G062,
96G073, 96G082, 96G086,
96G090, 96G094, 96G101,
96G113, 96G115, 96G116,
96G128, 96G132, 96G133
1
1
1
1
1
1
1
2
3A0414N
Parts
Ref
Part
Description
PLATE, follower, 2 liter models
96G004, 96G006, 96G008,
96G010, 96G012, 96G014
PLATE, follower, 4 liter models
96G046, 96G053, 96G062,
96G073, 96G082, 96G086,
96G090, 96G094, 96G101,
96G113, 96G115, 96G116,
96G128, 96G132, 96G133
ROD, follower plate, 2 liter models
43
96G004, 96G006, 96G008,
96G010, 96G012, 96G014
ROD, follower, 4 liter models
96G046, 96G053, 96G062,
96G073, 96G082, 96G086,
96G090, 96G094, 96G101,
96G113, 96G115, 96G116,
96G128, 96G132, 96G133
SPRING, compression, 2 liter models 96G004, 96G006, 96G008,
96G010, 96G012, 96G014,
44
96G016, 96G018, 96G020,
96G022, 96G024, 96G026
SPRING, compression, 4 liter models 96G046, 96G053, 96G062,
96G073, 96G082, 96G086,
96G090, 96G094, 96G101,
96G113, 96G115, 96G116,
96G128, 96G132, 96G133
BAFFLE, low level, 2 liter models
96G003, 96G005, 96G009,
96G011, 96G013, 96G015,
45† 24D838 96G017, 96G019, 96G021,
96G023, 96G025, 96G030 96G037, 96G098, 96G110,
96G125, 96G178
BAFFLE, low level, 4 liter models
96G038, 96G044, 96G048,
96G055, 96G064, 96G068,
96G075, 96G084, 96G088,
96G092, 96G096, 96G099,
†
24E246 96G103, 96G111, 96G118,
96G126, 96G141, 96G143,
96G145, 96G147, 96G149,
96G151, 96G153, 96G155,
96G157, 96G159, 96G160,
96G161, 96G162
42
3A0414N
Qty
Ref
Part
1
†
24F836
†
24F923
†
24F924
57
117156
58
196548
1
1
1
1
1
Description
BAFFLE, low level, 8 liter models
96G045, 96G049, 96G056,
96G065, 96G069, 96G076,
96G085, 96G089, 96G093,
96G097, 96G100, 96G104,
96G112, 96G119, 96G127,
96G142, 96G144, 96G146,
96G148, 96G150, 96G152,
96G154, 96G156, 96G158,
96G177
BAFFLE, low level, 12 liter models
96G057, 96G077, 96G105,
96G120
BAFFLE, low level, 16 liter models
96G058, 96G078, 96G106,
96G121
BEARING, sleeve, models
96G003-96G026, 96G033-96G038,
96G044-96G046, 96G048,
96G049, 96G053,
96G055-96G058, 96G062,
96G064, 96G065, 96G068,
96G069, 96G073,
96G075-96G078, 96G082,
96G084-96G086, 96G088-96G090,
96G092-96G094, 96G096-96G101,
96G103-96G106, 96G110-96G113,
96G115, 96G116,
96G118-96G121, 96G125-96G128,
96G132, 96G133,
96G141-96G165, 96G177, 96G178
LABEL, models 96G002, 96G007,
96G008, 96G014, 96G032,
96G037, 96G042, 96G043,
96G055-96G062, 96G075-96G082,
96G092-96G094, 96G118-96G128,
96G132, 96G133, 96G139,
96G140, 96G145, 96G146
Qty
1
1
1
1
1
1
75
Parts
Ref
60
61
Part
Description
WASHER, low level, models
96G003-96G026, 96G033-96G038,
96G044-96G046, 96G048,
96G049, 96G053,
96G055-96G058, 96G062,
96G064, 96G065, 96G068,
96G069, 96G073,
16D984 96G075-96G078, 96G082,
96G084-96G086, 96G088-96G090,
96G092-96G094, 96G096-96G101,
96G103-96G106, 96G110-96G113,
96G115, 96G116,
96G118-96G121, 96G125-96G128,
96G132, 96G133,
96G141-96G165, 96G177, 96G178
RESERVOIR, mid-section, 8 liter
models 96G039, 96G041, 96G043,
96G045, 96G049, 96G052,
96G056, 96G061, 96G065,
96G069, 96G072, 96G076,
96G081, 96G085, 96G089,
96G093, 96G097, 96G100,
96G104, 96G109, 96G112,
96G119, 96G124, 96G127,
96G136, 96G138, 96G140,
96G142, 96G144, 96G146,
96G148, 96G150, 96G152,
96G154, 96G156, 96G158,
96G177
RESERVOIR, mid-section, 12 liter
models 96G057, 96G077, 96G105,
96G120, 96G163-96G165
RESERVOIR, mid-section, 16 liter
models 96G058, 96G078, 96G106,
96G121
Qty
Ref
Part
2
62
1
66
126417
67
24N806
2
3
123749
123750
200
125298
126083
123358
76
Description
Qty
ADAPTER, reservoir, models
96G038-96G046, 96G048,
96G049, 96G051-96G053,
96G055, 96G057, 96G058,
96G060-96G062, 96G064-96G066,
96G068, 96G069,
96G071- 96G073, 96G07596G078, 96G080-96G082,
96G084-96G086, 96G088-96G090,
96G092-96G094, 96G096,
96G097, 96G099-96G101,
96G103-96G106, 96G108,
96G109, 96G111-96G113,
96G116,
96G118-96G121, 96G123,
96G124, 96G126-96G128,
96G133, 96G135-96G149,
96G151, 96G153, 96G155,
96G157, 96G159- 96G165,
96G177
NUT, models 96G050, 96G051,
96G052, 96G059, 96G060,
96G061, 96G070, 96G071,
96G072, 96G079, 96G080,
96G081, 96G107, 96G108,
96G109, 96G122, 96G1223,
96G124, 96G174, 96G175,
96G176
FLOAT, oil, models 96G050,
96G051, 96G052, 96G059,
96G060, 96G061, 96G070,
96G071, 96G072, 96G079,
96G080, 96G081, 96G107,
96G108, 96G109, 96G122,
96G1223, 96G124, 96G174,
96G175, 96G176
CABLE,15 ft (4.5 m), SOOW
w/7pos, 3 pin, 90 deg (See Wiring
Diagram, page 23)
CABLE, 15 ft (4.5 m), SOOW w/7
pos, 5 pin, 90 deg, (See Wiring Diagram, page 24)
CABLE, 20 ft (6.1 m), SOOW, w/7
pos, 5 pin, 90 deg, (See Wiring Diagram, page 24)
CABLE, 30 ft (9.1m) SOOW, w/7
pos, 5 pin, 90 deg, (See Wiring Diagram, page 24)
CABLE, DIN, bare, (See Wiring
Diagram, page 25)
1
1
1
1
1
3A0414N
Parts
Ref
Part
Description
Qty
CABLE, M12, 15 ft., 4 wire, straight
124300 male to flying leads (See Wiring
Diagram, page 26)
201
CABLE, M12, 15 ft., 4 wire, straight
124333 male to female (See Wiring Diagram, page 26)
CONNECTOR, Eurofast, fem,
124301
straight, 4P
CONNECTOR, Eurofast, 4 Pin (see
202 124594
wiring diagram, page 27
CONNECTOR, Eurofast, 5 Pin (see
124595
wiring diagram, page 27
1
1
1
1
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
‡ For Pro Models Only - Also order Ref 31, Part No.
119228 and Ref 34, Part No. 16A578
‡ For Max Models Only - Also order Ref 31, Part No.
119228 and Ref 34, Part No. 16A073
† Also order Ref. 57, Part No. 117156 when ordering
this part.
3A0414N
77
Parts
Pressure Relief Valves
Fuses
Important Information regarding Pressure Relief
Valve 16C807.
Part
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
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
16C807
563156
563157
563158
563159
563160
563161
563190
78
Description
VALVE, pressure relief, 500-3500 psi
(3.44 MPa, 34.4 bar - 24.1 MPa, 241
bar), Set pressure 3000 psi + 10%
(20.68 MPa, 206.8 bar + 10%)
Included in Kit 571028
VALVE, pressure relief, 750 psi (5.17
MPa, 51.71 bar)
VALVE, pressure relief, 1000 psi (6.89
MPa, 68.95 bar)
VALVE, pressure relief, 1500 psi
(10.34 MPa, 103.42 bar)
VALVE, pressure relief, 2000 psi
(13.78 MPa, 137.89 bar)
VALVE, pressure relief, 2500 psi
(17.23 MPa, 172.36 bar)
VALVE, pressure relief, 3000 psi
(20.68 MPa, 206.84 bar)
VALVE, pressure relief, 5500 psi
(37.92 MPa, 379.21 bar)
Qty
1
1
1
1
1
1
1
1
Qty
571039 FUSE, 12 volt DC
1
571040 FUSE, 24 volt DC
1
Installation and Repair Kits
Kit No.
ti15644
Description
Description
571026 KIT, output union, 3 pump
571063 KIT, output union, 2 pump
KIT, return to reservoir NPT,
571028 includes pressure relief valve
16C807
KIT, return to reservoir BSPP,
571071 includes pressure relief valve
16C807
571029 KIT, vent valve, 24 volt DC, NPT
571061 KIT, vent valve, 12 volt DC, NPT
24F536 KIT, vent valve, 24 volt DC, BSPP
24F537 KIT, vent valve, 12 volt DC, BSPP
571030 KIT, remote manual run, 12 volt DC
571031 KIT, remote manual run, 24 volt DC
KIT, remote manual run, 12 volt DC,
571032
with cable
KIT, remote manual run, 24 volt DC
571033
with cable
571036 KIT, cover with “G” label
KIT, pump element, includes Ref
571041
17, 18, 33
KIT, repair, 2 liter reservoir,
571042
includes Ref 13, 36, 40
KIT, repair, 2 liter reservoir, for
571069 models with follower plate, includes
Ref 13, 36, 40
KIT, replacement, paddle, 2 liter, for
571044 models without follower plate,
includes Ref 13, 16, 35, 57
KIT, replacement, paddle, 2 liter, for
571045 models with follower plate, includes
Ref 13, 16, 35,40a, 42, 57
KIT, replacement, paddle, 4-16 liter,
571046 for models without follower plate,
includes Ref 13, 16, 35, 57
KIT, replacement, paddle, 4 liter, for
571047 models with follower plate, includes
Ref 13, 16, 35, 57
Manual
Number
3A0523
3A0525
3A0526
3A0528
NA
3A0533
3A0534
3A0535
3A0414N
Parts
Kit No.
Description
Manual
Number
571058 KIT, output adapter, NPT
3A0522
571070 KIT, output, adapter, BSPP
571060 KIT, fill, zerk, leakproof
NA
KIT, repair, reservoir oil, 2 liter mod571179
els, includes Ref 13, 36, 40b
KIT, repair, reservoir, oil 4 liter mod571182
3A0534
els, includes Ref 13, 36, 40b
KIT, repair, reservoir, grease, 4 liter
571183
models, includes Ref 13, 36, 40b
3A0414N
79
Parts - 2 Liter Models
Parts - 2 Liter Models
40b
Follower Plate
Models Only
Low Level Grease Models Only
40a
43
45
44
35
42
57
27 1
41
60
16
36
23
15
13
Low Level Oil Models Only
14
67
18
3 37
21
1
31
66
33
17 3
34
3
4 2
30
1 Torque to 4 in. lbs (0.45 N.m)
ti15387
2 Torque to 30 in. lbs (3.4 N.m)
3 Torque to 50 in. lbs (5.6 N.m)
80
3A0414N
Parts - 4 Liter and Larger Models
Parts - 4 Liter and Larger Models
Follower Plate
Models Only
40a
40b
43
44
Low Level Grease Models Only
41
45
36
42
35
57
61
27 1
60
16
62
23
13
14
15
18
Low Level Oil Models Only
3 37
21
1
31
67
33
17 3
34
4 2
ti15387
30
3
66
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)
3A0414N
81
Technical Data
Technical Data
A
Maximum Working 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
5100 psi (35.1 MPa, 351.6 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
Outputs - Vent Valve
Required Vent Valve Type
Normally closed
Output Voltage
100/240 VAC
24 VDC
12 VDC
Input Voltage
24 VDC
Input Voltage
Max Operating Current
2A
Max Operating Power
48 W
Outputs - Low Level (Dry Contact)(G3 Standard/No Controller units)
Contact Rating
10 Watts Maximum
Switch Rating
200 VDC Maximum
Switching Current
0.5 A Maximum
Carry Current
1.2 A Maximum
Inputs - Cycle Pressure, 1, 2, 3, Machine Count
Required Switch Type
Normally open (sink, source, or dry contact)
Sensor Voltage
100/240 VAC
24 VDC
12 VDC
Input Voltage
24 VDC
Input Voltage
Load Current
100/240 VAC
22mA @ 24 VDC
12 VDC
11mA @ 12 VDC
24 VDC
22mA @ 24 VDC
Maximum Residual Voltage
100/240 VAC
4V
12 VDC
2V
24 VDC
4V
Maximum Off Current
100/240 VAC
1.5 mA
12 VDC
1 mA
24 VDC
1.5 mA
Input Impedance
1.1 K
Response Time
60 ms
Cycle Rate
8.0 Hz (50% duty cycle)
82
3A0414N
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 Liters
IP69K
3 (any of pressure or cycle)
1 (machine count)
-13°F - 158°F (-25°C to 70°C)
13.3 lbs (6.03 kg)
14.2 lbs (6.44 kg)
nylon 6/6 (PA), trogamid T5004-060, zinc plated steel,
carbon steel, alloy steel, stainless steel, nitrile rubber
(buna-N), bronze, nickel plated alnico, chemically lubricated acetal, aluminum, PTFE, Grillamid
<60 dB
Dimensions
Model
2L
4L
8L
12L
16L
3A0414N
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
83
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. 29
84
3A0414N
Notes
Notes
3A0414N
85
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.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 3A0414
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised November 2012

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