Graco 332298B User Manual

Instructions

Conforms to ANSI/UL 73 Certified to CAN/CSA Std. 22.2 No 68-09

3132066

G3 Pro Automatic

332298B

Lubrication Pump

For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For Professional Use Only.

Not approved for use in explosive atmospheres or hazardous locations.

Part Nos., page 3

5100 psi (35.1 MPa, 351.6 bar) Maximum Working Pressure

Important Safety Instructions Read all warnings and instructions in this

manual. Save these instructions.

Table of Contents

Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3

2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Understanding the Model Number . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 8

Choosing an Installation Location . . . . . . . . . . . . 9

System Configuration and Wiring . . . . . . . . . . . 10

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connecting to Auxiliary Fittings . . . . . . . . . . . . . 18

Setting Pump Outlet Volume . . . . . . . . . . . . . . . 19

Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 19

Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 21

Pro Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Control Panel Overview . . . . . . . . . . . . . . . . . . 22

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Advanced Programming . . . . . . . . . . . . . . . . . . . . 26

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 30

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 33

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 34

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 41

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42

Graco Information . . . . . . . . . . . . . . . . . . . . . . . 42

2 332298B

96G078 G3-G-ACPR-160L00-0D000000 96G167 G3-G-24PR-160L05-00C00000

Model Numbers

332298B 3

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.

G3 -G - PR 0 00 0

Code Sample: a a b b - c c d e f f - g h i j k m n p

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

Code bb: Operation Control

• PR = Pro (Timer) Control

Code cc: Reservoir Capacity (Liters)

• 2L = 2 Liters

• 4L = 4 Liters

• 8L = 8 Liters

• 12 = 12 Liters

• 16 = 16 Liters

Code d: Follower Plate Installed

• F = Follower Plate Installed

• 0 = No Follower Plate

Code e: Low Level Option

• L = Low Level with Controller

• 0 = No Low Level monitoring

Code ff: Options

• 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 F

•C = CPC

•D = DIN

• R = Remote Manual Run

• 0 = Not populated

IG. 1 for these locations.

FIG. 1

4 332298B

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

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

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

332298B 5

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, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

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

6 332298B

Installation

G3-G-24PR-2LFL00-R0C00000

Grease Models with Follower Plate

96GXXX

Oil Models

Grease Models

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

FIG. 2:

Key:

A Reservoir B Adjustable Pump Element (1 included. Can accommodate

C Pressure Relief Valve (Not included / required for each

D Zerk Inlet Fill Fitting (1 included / grease models only) E Pump Outlet Plug (2 included) F Volume Control Spacers (2 included. More spacers = less

G Fuse (DC models only - Not included, not shown.

332298B 7

3 total)

outlet - Available from Graco. See Parts, page 38.)

output volume per stroke) (also see F

Available from Graco. See Parts, page 38.)

H Control Panel I Power / Sensor Panel (both sides; only one side shown) J Part Number / Model Number example only shown, (see

pages 4, Understanding the Model Number, for details) K Power Cord (DIN shown) L Follower Plate (grease models only / not available on all

M Vent Hole for Follower Plate (grease models only / not

IG. 12, page 19)

N Fill cap (oil models only)

grease models)

available on all grease models)

Installation

Typical Installation

Divider Installations

A Connected to fuse / power B Pressure relief valve (Not included/required for each

outlet - user supplied. See Parts, page 38)

C - Cycle indicator sensor cable to external controller

(Divider Installations)

- Pressure switch cable to external controller (Injector Installations)

D - Series progressive divider valves (Divider Installations)

- Injectors (Injector Installations) E To lube points F - Proximity Switch (Divider Installations)

- Pressure switch (Injector Installations)

8 332298B

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.

• Refer to the two mounting hole layouts provided in the Mounting Pattern section of this manual, page 41.

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.

• Always mount the G3 oil models upright.

• If the G3 grease model is going to be operated in a tilted or inverted position for any period of time, you must use a model that includes a follower plate, otherwise the G3 must be mounted upright. Refer to your model number to confirm if a follower plate was installed on your pump. See page 4, 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.

332298B 9

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.

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.

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.

Input Voltage

12 VDC 24 VDC

Fuse Value

7.5 A 4 A

Graco Kit No.

571039 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.

10 332298B

Installation

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)

Unit in OFF Mode Off Off Unit in ON Mode On Green Warning Condition Toggles On and Off once per second Yellow Fault Condition Toggles On and Off once per second Red

Tri-Color Remote Illumination

(via illuminated manual run input)

Wiring and Installation Diagrams

The following Table identifies the wiring and installation diagrams provided in this manual.

Diagram Symbol Page #

Power DIN AC 12

Power DIN DC 13

Power CPC DC 15

Illuminated Manual Run Input

Kits: 571030, 571031, 571032, 571033

332298B 11

Installation

(4)

(2)

(1)

Example Wiring Diagram

Connector on Housing

Connector on Cable

(4)

(1)

(3)

(2)

Power DIN AC - 15 foot: Part No. 16U790

Pin and Related Wire Color (FIG. 3)

Pin Pin Name Color

1 Line Black 2 NEUTRAL White 3 Not Used Not Used 4GROUND Green

FIG. 3

12 332298B

Power DIN DC - 15 Foot: Part No. 16U790

Ignition Switch

Fuse

Example Wiring Diagram

Connector on Housing

12V-pump - 7.5A - Graco kit #571039 24V pump - 4A - Graco kit #571040

(4)

(2)

(1)

Connector on Cable

(4)

(1)

(3)

(2)

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.

Pin and Related Wire Color (FIG. 4)

Installation

Pin Pin Name Color

1-VDC Black 2+VDC White 3 Not used Not used 4 Not used Green

FIG. 4

332298B 13

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