Graco 332514J User Manual

Instructions

Dyna-Star

HP and

332514J

HF Pump

Provides lubricant flow and pressure to operate a single line automatic lubrication system. For automatic lubrication systems only. For professional use only. Not approved for use in explosive atmospheres or hazardous locations.

Important Safety Instructions Read all warnings and instructions in this

manual. Save these instructions.

Models: Page 2

Models

Pump

Models

77X000 X X X

77X001 X X X X

77X002 X X X X

77X003 X X X X

77X011 X X X X X

77X012 X X X X X

77X013 X X X X X

77X014 X X X

77X015 X X X

77X016 X X X

Tube in

Tube

Pump

Vent

Valve

Compatible Reservoirs Maximum Working Pressure

35/60

Pound

90/120 Pound

400

Pound

3500 psi

24.1 MPa, 241 bar

5000 psi

34.47 MPa, 344 bar

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Warnings

WARNINGWARNINGWARNING

WARNING

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.

FIRE AND EXPLOSION HAZARD

When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be aware that flammable fumes can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources, such as cigarettes and portable electric lamps.

• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Ground all equipment in the work area.

• Use only grounded hoses.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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.

332514J 3

Warnings

WARNINGWARNINGWARNING

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.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

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.

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.

4 332514J

Warnings

WARNINGWARNINGWARNING

WARNING

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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 manufacturers.

332514J 5

Typical Installation: Injector System

FrontBack

Low Reservoir Level Switch

(Level Indicator,

optional)

Pressure Switch for System Control

Remote Alarm Device

(Light or Horn)

(user provided

Controller Capabilities

Motor Control Board

Pump Power

Pump Signal

Vent Valve

Typical Installation: Injector System

The installation shown in below is only a guide for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs.

FIG. 1

Key:

A Lubricant output connection B Pump C Ignition switch* D High-pressure lubricant supply lines* E Injector banks* F Lubrication controller* G Fill port (for reference only; non-tube-in-tube models only) H Overflow port (for reference only) J Breather (for reference only)

K Reservoir / Tank L Vent Valve (for reference only) M Motor

*User provided

6 332514J

Typical Installation: Series Progressive System

FrontBack

Low Reservoir Level Switch

(Level Indicator,

optional)

Pressure Switch for System Control

Remote Alarm Device

(Light or Horn)

(user provided

Controller Capabilities

Motor Control Board

Pump Power

Pump Signal

Typical Installation: Series Progressive System

The installation shown below is only a guide for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs.

FIG. 2

Key:

A Lubricant output connection B Pump C Ignition switch* D High-pressure lubricant supply lines* E Primary metering device* F Lubrication controller* G Fill port (for reference only; non-tube-in-tube models only) H Overflow port (for reference only) J Breather (for reference only) K Reservoir / Tank (for reference only)

L Secondary metering device M Motor N Bearing

*User provided

332514J 7

Installation

126

128

Installation

Pressure Relief

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing the equipment.

To relieve pressure in the system, use two wrenches working in opposite directions on pump outlet fitting to slowly loosen fitting only until fitting is loose; no more lubricant or air is leaking from fitting as shown in F

IG. 3.

• Install tank / reservoir cover on tank / reservoir. Tighten screws to secure cover to tank / reservoir.

1. Remove pump mounting screws (a) and washers (b) from tank / reservoir cover. Save these parts. Gasket (c) should not be removed from the cover. These parts will be used to install the pump to the tank / reservoir cover for reassembly.

FIG. 4: 120 Pound Cover Shown

2. Loosen bolts (128) and remove cover (126) from Dyna-Star pump (F

IG. 5).

FIG. 3

Pump Module

Reference numbers used in the following instructions refer to Parts, page 35. Upper case reference letters used in the following instructions refer to Typical Installation Drawings provided on pages 6 and 7.

NOTE:

• Tank / reservoir covers and reservoirs are available from Graco. Contact your Graco Distributor or Graco Customer Service for assistance ordering these parts. See Parts, page 38 for a complete list of accessories.

• Before installing pump on tank / reservoir, use bolts to secure tank / reservoir to it’s installation location.

8 332514J

FIG. 5

3. Remove protective cap (d) from pump down-tube (208) (F

IG. 6). Discard cap. You will not use it again.

208

FIG. 8

115

133

Installation

FIG. 6

4. Verify gasket (c) is in place on top the reservoir cover, laying flat and that the holes (e) in the gasket align with the holes in the cover (F

IG. 7).

FIG. 7

HEAVY EQUIPMENT HAZARD

Lifting or moving heavy equipment incorrectly can cause serious injury. To avoid serious injuries, such as muscle strain or back injuries, when moving pump always use a lifting aid secured to the pump lift ring . See Technical Data, included in the pump instruction manual for pump weight information.

5. Install pump down-tube through opening in the center of the gasket and tank / reservoir cover and into tank / reservoir.

6. Align holes in pump base with holes in tank / reservoir cover (F

IG. 8). Securely fasten pump to tank /

reservoir cover using screws (a) and washers (b) removed in Step 1, page 8.

NOTE: When the pump is correctly installed on the Graco tank, the breather (J) will be below the control box (115) as shown in F

IG. 9.

FIG. 9

NOTICE

To prevent damage to the unit:

• Check breather (J) vent for proper operation before filling reservoir.

• Open overflow port (H) before filling reservoir to visually inspect lubrication level.

• Do not fill reservoir beyond overflow port (H).

• Do not use breather vent as a port to fill reservoir.

7. Reinstall cover (126) using bolts (128). Use a wrench to tighten bolts securely (F

IG. 10).

332514J 9

Wiring

126

128

Wiring

Grounding

The equipment must be bonded (grounded) directly to the truck. Grounding reduces the risk of static shock due to static build up on the equipment.

FIG. 10

8. Connect the timer/controller (F) (user supplied, if used).

9. Connect High Pressure Lubricant Supply Line (D) to the Lubricant Output Connection (0) (F Vent Valve or Manifold.

NOTE: The High Pressure Lubricant Supply Line (D) is disconnected from the Lubricant Output Connection (0) during Priming, page 15.

FIG. 11: Lubricant Outlet Connection

IG. 11) on the

System Configuration and Wiring

NOTE: Cable wiring harness kits are available from

Graco. See Parts page 38 for a complete list of available kits.

Fuses

NOTICE

Fuses (user supplied) are required on all models. To avoid equipment damage:

• Never operate the Dyna-Star Pump models without a fuse installed.

• A fuse of the correct voltage and amperage must be installed in line with the power entry to the system. Graco recommends using 35A fuses.

10 332514J

Wiring

116

120

119

115

Installation Instructions

Reference numbers used in the following instructions refer to Parts, page 36.

1. Remove screws (116), cover (120) and gasket (119) to access motor lead wires (F

2. Feed the incoming power source wires through the strain relief body (SR) and into the gear housing (F

IG. 12).

a. Tighten the strain relief body (SR) to the gear

housing (115) to 5.1 ft.-lbs (7.0 N.m).

b. Tighten the compression nut (CN) to 3.7 ft.-lbs

(5.0 N.m).

NOTE: See Technical Data, page 39 for wire O.D. specifications to verify correct cable is used.

3. Make all source to input power connections (A and B, page 13) and pump control connections (C and D, page 13). Refer to F wiring diagrams and Control Board diagram, page

13.

IG. 12).

IG. 13 or FIG. 14, page 12 for

4. Route wires into box. Replace gasket (119) cover (120) and screws (116), being careful not to pinch any wires. Tighten bolts securely. Torque bolts to 17-19 ft.-lbs (23-26 N.m).

FIG. 12

NOTICE

To avoid equipment damage, remove power before switching modes from signal to power or power to signal.

332514J 11

Wiring

35 A

18 - 32VDC

5 - 32VDC

Sig In

SigPwr

Electric Vent * Valve

Motor Control Board

Lubrication

Controller

Pump Output

40A Relay

Sig In

SigPwr

35 A

Pump Output

18 - 32VDC

5 - 32VDC

Electric Vent * Valve

Motor Control Board

Lubrication

Controller

24 VDC With Signal Input

FIG. 13: Pump control switch shown in signal mode

*A Vent Valve is only used in an injector-based system.

24 VDC With External Relay

FIG. 14: Pump controls switch shown in power mode

*A Vent Valve is only used in an injector-based system.

12 332514J

DC Models - Motor Control Board

MAX

MIN

SPEED

CURRENT

SIGPWR

BLUE

YELLOW

GREEN

F E

Wiring

FIG. 15

Key

A - (Negative) Power Input

B + (Positive) Power Input

C Turn On Signal 

D Turn On Signal +

E Red (Fault) LED - Blinks type of fault (See Fault Table)

F Green (Power) LED -

• Blinks: Power ON, Pump running

• Solid: Power/Pump OFF

G Current Control Potentiometer (Minimum: Turn Knob

Counter-Clockwise / Maximum: Turn Knob Clockwise)

H Flow Control Potentiometer (Minimum: Turn Knob

Counter-Clockwise / Maximum: Turn Knob Clockwise)

J Pump Control Switch*

• PWR - Turns pump on when power is applied

• SIG - Turns pump on when voltage is applied to:

- SIG IN 

K Blue Motor Wire Connection

L Yellow Motor Wire Connection

M Green Motor Wire Connection

N J5 Connector - Motor Hall Cable Connector

332514J 13

- SIG IN +

Fault Table: Red LED (E)

Fault Blinks

Over Current 1

Locked Rotor 2

Low or High Voltage 3

High Motor temp 4

Missing Temp Sensor 5

High Board Temp 6

Bad Hall Cable 7

*NOTE: Be sure power to pump is OFF before switching between the PWR and SIG modes.

Wiring

in3/min.

Current Control and Flow Motor Control Settings

Current and Flow control are adjusted on the Motor Control Board using the Current Control Potentiometer Knob (G) and the Flow Control Potentiometer Knob (H) (page 13). Turn knob to clockwise to increase setting value. Turn knob counter-clockwise to decrease setting value.

The Current Control knob (G) governs flow. The Current setting has precedence over the Flow Rate setting. You may be limited in achievable Flow Rate by the Current setting.

See Performance Charts, page 41 for Flow Rate and Current information.

NOTE: Values are based on lab test conditions at ambient temperature 72°F (22°C) with an input voltage of 24V. Actual results may very and should be verified in the application.

HF Current HF Flow

Amps

HP Current HP Flow

Amps

14 332514J

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