Graco 3A2100C User Manual

Instructions

Modular Box

3A2100C

Lubricator

Fluid container used with GBL7500 Suction Fed, Gravity Fed or Pressure Fed Box Lubricator Pumps used for dispensing non-corrosive and non-abrasive oils and lubricants. For professional use only.

See Technical Data, page 13 for maximum outlet pressures per pump station.

Important Safety Instructions

Read all warnings and instructions in this manual and your pump instruction manual. Save all instructions.

See page 2 for part number information.

ti17757

Part Number

Use the Part Number Key provided below to identify each system component. The Code for each Option that makes up the Part Number are provided in the tables below. For example, MBB1DE is a Modular Box; 6 pint reservoir, (maximum of 3 pumping stations and no motor mount base); 3/16 suction fed pump; 3 pumps; and a direct end rotary drive. NOTE: Some pump configurations are not available. Contact Graco Customer Service or your local Graco distributor for assistance.

Par t Key: MB Part Example: MB

A-B -C-D B-1 -D-E

MB = Identifies pump as Graco MB part

Option A: Reservoir Size and Motor Mount Base

Code

A 4 (1.89) 2 NA

B 6 (2.84) 3 NA

C 8 (3.79) 5 NA

D 12 (5.68) 8 NA

E 16 (7.57) 12 NA

F 24 (11.36) 16 NA

G 32 (15.14) 20 NA

H 40 (18.93) 24 NA

J 4 (1.89) 2 X

K 6 (2.84) 3 X

L 8 (3.79) 5 X

M 12 (5.68) 8 X

N 16 (7.57) 12 X

P 24 (11.36) 16 X

R 32 (15.14) 20 X

S 40 (18.93) 24 X

Reservoir Size:

pints (liters)

Max Number

of Pump Stations

Motor Mount

Base

Option B: GBL7500 Pump and Level Controller

Code

0◆ No Pump

1◆ 3/16 Suction Fed Pump

2◆ 1/4 Suction Fed Pump

3◆ 3/8 Suction Fed Pump

4 3/16 Suction Fed Pump with RENS Level Controller

5 1/4 Suction Fed Pump with RENS Level Controller

6 3/8 Suction Fed Pump with RENS Level Controller

3/16 Suction Fed Pump with GARZO Level Controller (Class 1, Group D) 1/4 Suction Fed Pump with GARZO Level Controller (Class 1, Group D) 3/8 Suction Fed Pump with GARZO Level Controller (Class 1, Group D)

Description

Option C: Pump Quantity

Code Quantity Code Quantity

A0N12

B1P13

C2R14

D3S15

E4T16

F5U17

G6V18

H7W19

J8X20

K9Y21

L10Z22

M11

Option D: Drive Type

Code Description

A◆ Direct end rotary X

End ratchet (w/out drive arm) - 800 rpm max

input

C End rotary ratchet 37.5:1 - 800 rpm max input X

D End rotary ratchet, 75:1 - 800 rpm max input X

E◆ Direct end rotary X

End ratchet (w/out drive arm) - 800 rpm max

input

G End rotary ratchet 37.5:1 - 800 rpm max input X

H End rotary ratchet, 75:1 - 800 rpm max input X

J Double reduction end rotary, 25:1 X

K Double reduction end rotary, 50:1 X

L Double reduction end rotary, 100:1 X

M Double reduction end rotary, 200:1 X

N Double reduction end rotary, 400:1 X

P Right angle rotary 25:1 X

R Right angle rotary 50:1 X

S Right angle rotary 188:1 X

T Right angle rotary 375:1 X

U 100:1 ratio gear reducer X

V 150:1 ratio gear reducer X

W 200:1 ratio gear reducer X

X 300:1 ratio gear reducer X

Y 400:1 ratio gear reducer X

Z Left angle rotary 188:1 X

Drive Side

Left Right

◆ Configurations containing these selections from both

Option B and Option D are CE and Atex certified.

II 2 G

cT6

2 3A2100C

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, 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

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 treat-

ment.

• 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.

3A2100C 3

Warnings

WARNING

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. 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.

PERSONAL PROTECTIVE EQUIPMENT

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

• Protective eye wear, and hearing protection.

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

4 3A2100C

Installation

Modular box lubricators are not approved for use in hazardous locations or explosive atmospheres unless all accessories, components and wiring meet all local and national codes.

Component Identification

ti17757

Grounding

The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.

J B

FIG. 2

1. Loosen grounding screw (a) (FIG. 2) and place one end of a 12 gauge (1.5mm) minimum ground wire between the grounding screw and washer (b).

FIG. 1

Key:

A Site glass B Fill cap CDrain plug D Pump blank E Drive shaft - (with woodruff key) F Mounting holes G Accessory plug (heater port) H Pump (not on all models)* J Mounting screw

*The GBL7500 Box Lubricator Pump and GBL Shaft Rotation/Low Level Alarm Pump are available from Graco. See Accessories/Other Accessories, page 12 for information about these pump models and the related instruction manual.

2. Tighten grounding screw (a) securely.

3. Connect other end of wire to a true earth ground.

Installation Procedure

Reference letters used in the following instructions, refer to F

IG. 1.

1. Select a mounting surface that satisfies the following:

• Is able to support the weight of the reservoir

and fluid when filled to capacity.

NOTE: When possible, mount to a surface that experiences little or no vibration.

• Allows easy access to the lubricator for filling

the reservoir and periodic maintenance.

• The lubricator must be connected to a ground

source.

2. Install reservoir to the mounting surface. See mounting hole layout in the Reservoir and Mounting Dimension section of this manual, page 14.

3. Install bolts through holes (F) in reservoir mounting bracket and tighten securely.

3A2100C 5

Installation

4. Remove fill cap (B) and fill reservoir with clean, filtered fluid until it reaches the full line on the sight glass.

NOTE:

• Filter oil with a minimum 25 micron strainer.

Depending on machine requirements it may be necessary to maintain a higher cleanliness level.

• A pump blank is provided to install over all

unused pump stations.

• Refer to pump instruction manual for pump

installation and priming instructions. (See page 12 for Graco pump model information.)

Drive Mechanism

A 5/8 in. diameter shaft is provided to connect the lubricator to a rotary power source. A woodruff key and key way on the shaft are provided to aid in connecting this source.

Pressure Relief Procedure

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 in your pump manual when you stop dispensing and before cleaning, checking, or servicing the equipment.

1. Stop lube pump.

2. If installed, close oil supply valve located upstream from pump.

3. If installed, open drain valve located downstream from the pump.

4. Slowly crack open fluid line fittings to relieve pressure.

Install protective guards around all drive components upon installation.

Notice

The recommended speed of the box lubricator cam shaft is 3 - 50 rpm. Do not exceed the maximum value of 50 rpm to avoid pump damage.

Refilling the Reservoir

When necessary, fill the lubricator reservoir with clean filtered lubricant until it reaches the fill line on the sight glass. A sight level gauge is provided on the reservoir to monitor the fluid level. The oil level should not be allowed to drop below the line indicating an empty reservoir.

Service/Maintenance

1. Follow the Pressure Relief Procedure before per- forming any service procedures.

2. Lubricator operation can be checked by observing the drip tube located within the sight glass well of your pump.

• If the correct pumping rate is maintained, no

servicing is required other than periodic replenishment of the reservoir.

• If the sight glass well pumps dry or no flow is

observed refer to the Troubleshooting Section, page 8.

3. Inspect box for worn or damaged components. Replace as necessary.

6 3A2100C

4. Clean lubricator periodically to eliminate contamination that may have occurred in the oil. To accomplish this:

Installation

a. Drain reservoir by removing drain plug (C) (F

IG.

1). Dispose of oil according to all applicable safety regulations.

b. Remove all pumping units.

c. Clean the pumps and reservoir by brushing

loose all foreign matter, dipping in solvent and blowing dry with compressed air.

d. Replace pumping units. Torque mounting

screws (J) to 110 in. lbs + +

1.13 N.m).

10 in. lbs. (12.43 N.m

e. Apply thread sealant (user supplied) to drain

plug (C) (F lbs +

IG. 1) and replace. Torque to 35 in.

5 in. lbs. (3.95 N.m + 0.6 N.m).

f. Fill reservoir. (See Refilling the Reservoir, page

6).

3A2100C 7

Troubleshooting

Problem Cause Solution

Sight well pumps dry

Low oil level in reservoir Add oil. See Refilling the Reservoir,

page 6.

Pump issue Refer to the Troubleshooting Section

of your pump instruction manual.

Low oil level in reservoir Add oil. See Refilling the Reservoir,

page 6.

Camshaft not rotating because rotatory power source is defective

No flow from pump outputs

Leaking from under pump Defective gasket Replace gasket.

Leaking from reservoir accessory plug

Leaking from reservoir drain plug

Camshaft not rotating because rotatory power source connection is defective

Broken camshaft Replace lubricator box.

Pump issue Refer to the Troubleshooting Section

Insufficient thread sealant

Replace rotary power source.

Fix rotary power source connection to lubricator box.

of your pump instruction manual.

Clean and replace thread sealant (user supplied).

8 3A2100C

+ 16 hidden pages