Graco 95G104 Manual Download Page 2

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3A8848A

Contents

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

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

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

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

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Identification . . . . . . . . . . . . . . . . . . 8

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 9

Pump to Point . . . . . . . . . . . . . . . . . . . . . . . . 9

Typical Installation - With Remote

Fill Manifold. . . . . . . . . . . . . . . . . . . . . . 10

Optional Installation - Without Remote

Fill Manifold. . . . . . . . . . . . . . . . . . . . . . 11

Choose an Installation Location . . . . . . . . . . . . 12

System Configuration and Wiring . . . . . . . . . . . 12

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Recommendations for Pump Usage in

Harsh Environments . . . . . . . . . . . . . . . 13

Remote Illumination Response . . . . . . . . . . 14

Wiring and Installation Diagrams. . . . . . . . . 14

Power DIN DC - 15 Foot. . . . . . . . . . . . 15

Power CPC DC - 2 Wire . . . . . . . . . . . . . . . 15

Power CPC DC - 5 Wire . . . . . . . . . . . . 16

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 17

Connect to Auxiliary Fittings . . . . . . . . . . . . . . . 17

Pressure Relief Valves . . . . . . . . . . . . . . . . . 17

Set Pump Output Points and Outlet Volume . . . 18

Load Pump with Grease . . . . . . . . . . . . . . . . . . 19

Models Without a Follower Plate. . . . . . . . . 19

Models With a JIC Side Vent. . . . . . . . . . . . 20

Models with Top Fill. . . . . . . . . . . . . . . . . . . 20

Models with a Follower Plate . . . . . . . . . . . 21

Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 21

Load Grease . . . . . . . . . . . . . . . . . . . . . . . . 21

Change Grease . . . . . . . . . . . . . . . . . . . . . . 22

Remote Fill with Remote Fill Manifold. . . . . 22

Remote Fill without Remote Fill Manifold . . 23

Remote Filling Station Pressure Relief . . . . 24

Fill with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 25

Quick Setup Guide. . . . . . . . . . . . . . . . . . . . . . . 26

Pro Model Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Control Panel Overview (F

. 22) . . . . . . . . . . . . 27

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Powering Units With Controllers . . . . . . . . . 28

Entering Setup Mode. . . . . . . . . . . . . . . . . . 28

Entering a PIN Code to Access Setup Mode28

ON Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

OFF Time . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Prelube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Prelube Delay. . . . . . . . . . . . . . . . . . . . . . . . 30

Advanced Programming. . . . . . . . . . . . . . . . . . . . . 31

Entering a PIN Code for the First Time . . . . 32

Entering Advanced Setup . . . . . . . . . . . . . . 32

Selecting Advanced Setup Options. . . . . . . 32

A2 - Low Level Alarm Time . . . . . . . . . . . . . 32

A5 - Active Alarm . . . . . . . . . . . . . . . . . . . . . 33

A7- Constant Alarm Output ON Fault . . . . . 34

A8 - 4 Digit Hour OFF Time . . . . . . . . . . . . . 34

Models with Firmware 6.03 and later. DMS

Models with Firmware 7.07 and later. . . . . . 35

A10 - Low Level Reset Upon Power On . . . 35

A11- Warning Off Through Alarm Relay. . . . 35

Models with Firmware 6.06 and later for

non-DMS models. Models with

Firmware 7.09 and later for DMS models . . 36

A12 - Prelube Sequences . . . . . . . . . . . . . . 36

A13- MM:SS OFF Time . . . . . . . . . . . . . . . . 36

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Time Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Manual Run Cycle . . . . . . . . . . . . . . . . . . . . 37

Additional Controls . . . . . . . . . . . . . . . . . . . 38

Manual Run Cycle . . . . . . . . . . . . . . . . . . . . 38

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 41

End of Product Life. . . . . . . . . . . . . . . . . . . . . . . 41

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2-Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4-Liter and Larger Models . . . . . . . . . . . . . . . . . 44

K its and Accessories . . . . . . . . . . . . . . . . . . . . . . . 47

Installation and Repair Kits. . . . . . . . . . . . . . . . . 47

Reservoir Conversion Kits . . . . . . . . . . . . . . . . . 47

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . 47

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Mount Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Technical Specifications . . . . . . . . . . . . . . . . . . . . 49

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 49

Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 50

Summary of Contents for 95G104

Page 1: ...r use in explosive atmospheres or hazardous classified locations Model Numbers page 3 4250 psi 29 3 MPa 293 bar Pump Output Pressure 5000 psi 34 5 MPa 344 8 bar Fill Inlet Pressure Related Manuals Imp...

Page 2: ...ime the Pump 25 Quick Setup Guide 26 Pro Model Setup 27 Control Panel Overview FIG 22 27 Instructions 28 Powering Units With Controllers 28 Entering Setup Mode 28 Entering a PIN Code to Access Setup M...

Page 3: ...nfigured number identifies the distinct features of a specific G5 pump To help with understanding each component that makes up the Model Number see Understanding the Model Number page 4 The following...

Page 4: ...24 Volts DC Code cc Operation Control PR Pro Timer Control Code dd Reservoir Capacity Liters 2L 2 Liters 4L 4 Liters 8L 8 Liters 12 12 Liters 16 16 Liters Code e Reservoir Feature F Follower Plate In...

Page 5: ...nce of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Specifications in all equipment manuals Use fluids and solve...

Page 6: ...ctions before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately PRESSURIZED EQUIPMENT HAZARD Over pressurization can result in equipment rupture and ser...

Page 7: ...g 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 inju...

Page 8: ...s only Not included not shown Available from Graco See Parts Page 43 H Control Panel J Power Sensor Panel both sides only one side shown K Part Number Model Number example only shown see Understanding...

Page 9: ...nt Key A Connected to fused power source B Pressure Relief Valve Not included required for each outlet user supplied See Parts page 43 C Series Progressive Divider Valves Divider Installations Injecto...

Page 10: ...5 Reservoir E Remote Fill Reservoir F Remote Fill Pump G Supply Hose user supplied H Air Supply to Refill Pump J Supply Hose user supplied K Pressure Relief Valve L Drain Hose M Fill Coupler Inlet qui...

Page 11: ...dead heads there is a leak in the system Key A G5 Pump B Auto Fill Shut Off Valve C Auto Fill Inlet D G5 Reservoir E Remote Fill Reservoir F Remote Fill Pump H Relief Valve J Supply Hose user supplied...

Page 12: ...nently connected it must be installed by a qualified electrician or serviceman connected to a grounded permanent wiring system If an attachment plug is required in the end use application it must be r...

Page 13: ...m harness with a right angle mating connector make sure that the connector does not exit the unit in the upward direction Use a corrosion preventative electrical grease on all contacts NOTICE Fuses us...

Page 14: ...to the power cable provided by Graco with this product Wiring and Installation Diagrams The following Table identifies the wiring and installation diagrams provided in this manual Standard Remote Ill...

Page 15: ...ire Part No 127783 15 ft 4 5 m Pin and Related Wire Color FIG 7 Pin Pin Name Color 1 VDC Black 2 VDC White 3 Not Used Not Used Not Used Green FIG 6 Pin Pin Name Color 1 Not Used Not Used 2 VDC Black 3...

Page 16: ...arting a manual run cycle if used in conjunction with a 5 wire CPC cable is available from Graco Con tact your local Graco distributor or Graco Customer Service for additional information about these...

Page 17: ...ure when you stop dispensing and before cleaning checking or servicing the equipment FIG 9 NOTICE Do not attach unsupported equipment to auxiliary fit tings such as fill ports and pump element Attachi...

Page 18: ...e Pressure Relief Procedure page 17 before making any adjustments to the pump volume 6 Use a wrench to turn the pump element counter clockwise to loosen Do not remove the entire pump element Only back...

Page 19: ...nlet fill fitting FIG 12 2 For higher viscosity fluids start the pump to rotate the stirring paddle during the fill to prevent air pockets from forming Do not exceed a 30 minute run time For models us...

Page 20: ...onnect is not available remove the power cord FIG 14 2 Clean the top of the lid and the area around the top of the reservoir to ensure that no debris falls into the reservoir when the lid is removed 3...

Page 21: ...ove the fill hose Auto Fill Shut Off The Auto Fill Shut Off is used for refilling the G5 reservoir in an automatic lubrication system As fluid is added to the reservoir the plate valve is pushed up to...

Page 22: ...stall dead heads there is a leak in the system NOTICE Use care when filling the reservoir with a pneumatic or an electric transfer pump to not pressurize and break the reservoir The remote filling sta...

Page 23: ...drains during pressure relief must be installed in an easily accessible location between the remote filling station pump F and the auto fill shut off valve B This pressure relief valve is used to reli...

Page 24: ...ppropriate for the 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 p...

Page 25: ...p element fitting using two wrenches working in opposite directions FIG 20 2 Run the pump until air free lubricant is dispensed out of the element fitting FIG 21 3 Tighten the pump element fitting usi...

Page 26: ...Operation 26 3A8848A Quick Setup Guide...

Page 27: ...a set time to zero ALARM ICONS LED next to icon lights when a fault warning event occurs during a run cycle See page 39 for a complete description of these alarm scenarios LOCK ICON LED next to icon l...

Page 28: ...tions on entering a value Entering a PIN Code to Access Setup Mode The G5 controller does not require a user to provide a PIN code to access the programming features of the unit However Graco understa...

Page 29: ...lection 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...

Page 30: ...ENTER button to set the selection 4 For setting a prelube delay time press the DOWN ARROW but ton to change OFF to ON on the display Prelube Delay Prelube Delay can be entered to delay the start of t...

Page 31: ...te alarm with power ON and deactivate with power OFF OR warning Used to manage power outage A7 Constant Alarm Output on Fault Changes alarm output behavior Default OFF This function changes the behavi...

Page 32: ...Code and exit Advanced Setup Entering Advanced Setup Press the UP ARROW button for 10 sec onds If the G5 was previously set up to require a PIN Code the LED next to the LOCK ICON lights indicating a P...

Page 33: ...mber 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 th...

Page 34: ...n the display to change the alarm output to be on steady 3 Press the ENTER button to exit Advanced Programming A8 4 Digit Hour OFF Time Changes the OFF time from HH MM to HHHH Allows for a maximum of...

Page 35: ...OFF is dis played The alarm output will toggle once a sec ond 2 Press the UP or DOWN ARROW button to change OFF to ON on the display to change the low level reset upon power on 3 Press the ENTER butt...

Page 36: ...sequence 2 Press the UP or DOWN ARROW button until desired number of prelube sequences displays NOTE When prelube is on and the pump is pow ered up the pump will run this amount of lubrication ON seq...

Page 37: ...turns the pump on and it runs for the programmed ON Time cycle FIG 32 Notice the ON Time LED is now illuminated on the display The example shown in FIG 32 shows an ON Time of 8 minutes and 42 seconds...

Page 38: ...relube delay is set to something other than 00 00 Power to the unit cycles OFF then ON Unit immediately begins the Prelube Delay count down until the lubrication cycle begins The LED next to the clock...

Page 39: ...el Warning Level of lubricant in reservoir is low and addi tional lubricant needs to be added Unit continues to operate as normal for a limited period of time until a low level alarm is triggered Add...

Page 40: ...fittings clean using a clean dry cloth Dirt and or debris can damage pump and or lubrication system Daily G5 Pump Unit and Reservoir Keep pump unit and reservoir clean using a clean dry cloth Daily D...

Page 41: ...ge 17 Drain and dispose of fluids according to applicable regulations Refer to the material manufacturer s Safety Data Sheet Remove motors batteries circuit boards LCDs liquid crystal displays and oth...

Page 42: ...sa versa Verify the unit was programmed as intended referencing programming instructions Note the dot designa tion for hours minutes seconds on the top row of the display Lubricant leaks past seal loc...

Page 43: ...Plate Models Low Level Grease Models Low Level Oil Models Only Torque to 4 in lbs 0 45 N m 1 Torque to 30 in lbs 3 4 N m 2 Torque to 50 in lbs 5 6 N m 3 44 42 41 43 40b 40a 36 13 15 14 12 18 1 3 15 60...

Page 44: ...lower Plate Models Auto Fill Shut Off Models 4L Top Fill Reservoir 75 2 3 1 3 45 35 16 57 27 23 60 15 66 67 43 44 41 42 72 73 45 74 89 88 87 40c 36 82 83 81 84 85 4 3 34 30 33 17 18 1 12 31 37 21 13 1...

Page 45: ...24B702 RESERVOIR 4 Liter grease included in kit 571183 1 40b 16G020 RESERVOIR 4 Liter oil included in kit 571182 1 40c 17F484 RESERVOIR 4 Liter G5 AFSO 1 40d 133998 RESERVOIR 4 Liter side vent JIC 1 4...

Page 46: ...7 pos 5 pin 90 See Wiring and Installation Diagrams page 14 16U790 CABLE DIN bare See Wiring and Installation Diagrams page 14 1 201 124300 CABLE M12 16 5 FT 5 M 4 wire straight male to flying leads S...

Page 47: ...dle 2 liter for models with follower plate includes Ref 13 16 35 40a 42 57 571046 KIT replacement paddle 4 16 liter for models without follower plate includes Ref 13 16 35 57 571047 KIT replacement pa...

Page 48: ...ion 1 or Option 2 See P N 126916 template FIG 34 0 367inch 9 3 mm 2x 0 366 inch 9 3 mm 3 544 inch 90 0 mm 7 087 inch 180 0 mm 1 180 inch 30 0 mm 3 268 inch 83 0 mm 0 722 inch 18 3 mm 2x 0 366 inch 9 3...

Page 49: ...ir Size 2 4 8 12 16 Liters Reservoir Vent 8 JIC if equipped IP Rating IP69K Sensor Inputs 3 any of pressure or cycle 1 machine count Ambient Temps 40 F 158 F 40 C 70 C Noise dBa Maximum sound pressure...

Page 50: ...erial 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...

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