Graco 96G011 Instructions Manual Download

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332298J

Instructions

™

Pro Automatic

Lubrication Pump

For dispensing 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 (classified) locations.

Part Nos., page 3

5100 psi (35.1 MPa, 351.6 bar) Pump Output Pressure

5000 psi (34.4 MPa, 344.7 bar) Fill Inlet Pressure

Important Safety Instructions

Read all warnings and instructions in this

manual. Save all instructions.

Conforms to ANSI/UL 73

Certified to CAN/CSA

C22.2 No 68

3132066

24V and 100-240VAC Pumps ONLY

Summary of Contents for 96G011

Page 1: ...r use in explosive atmospheres or hazardous classified locations Part Nos page 3 5100 psi 35 1 MPa 351 6 bar Pump Output Pressure 5000 psi 34 4 MPa 344 7 bar Fill Inlet Pressure Important Safety Instructions Read all warnings and instructions in this manual Save all instructions Conforms to ANSI UL 73 Certified to CAN CSA C22 2 No 68 3132066 24V and 100 240VAC Pumps ONLY ...

Page 2: ...g Pump Outlet Volume 18 Loading Grease 18 Auto Fill Shut Off 21 Fill Oil Unit 23 Prime the Pump 24 Quick Setup Guide 25 Pro Model Setup 26 Control Panel Overview FIG 24 26 Instructions 27 Advanced Programming 30 Models with Firmware 6 03 and later DMS Models with Firmware 7 07 and later 34 Models with Firmware 6 06 and later for non DMS models Models with Firmware 7 09 and later for DMS models 35 ...

Page 3: ...24PR 2L0007 0D000000 Part Numbers Model Number 96G068 G3 G 24PR 4L0L00 R0C00000 X 96G071 G3 A 24PR 4L0L00 R0C00000 X 96G073 G3 G 24PR 4LFL00 R0C00000 X 96G075 G3 G ACPR 4L0L00 0D000000 X 96G080 G3 A ACPR 4L0L00 0D000000 X 96G082 G3 G ACPR 4LFL00 0D000000 X 96G135 G3 G 12PR 4L0000 00C00000 96G137 G3 G 24PR 4L0000 00C00000 X 96G139 G3 G ACPR 4L0000 0D000000 X 96G147 G3 G 12PR 4L0L05 00C00000 96G149 ...

Page 4: ... 240 Volts AC 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 Installed 0 No Follower Plate A Auto Fill Shut Off L Top Fill Code f Low Level Option L Low Level with Controller 0 No Low Level monitoring Code gg Options 00 No Options 05 5 Pin CPC power cable 07 No ...

Page 5: ...t 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 Spec ifications in all equipment manuals Read fluid and solvent manufacturer s warnings For com plete informa...

Page 6: ...ections 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 serious injury A pressure relief valve is required at each pump outlet Follow the Pressure Relief Procedure in this manual before servicing PLASTIC PARTS CLEANING SOLVENT HAZARD Many cleaning solvents c...

Page 7: ...ng 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 Protective equipment includes but is not limited to Protective eyewear and hearing protection Respirators protective clothing ...

Page 8: ...Not included not shown Available from Graco See Parts page 44 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 Not shown L Follower Plate grease models only not available on all grease models M Vent Hole for Follower Plate grease models only not available on all grea...

Page 9: ...ogressive Divider Valve Installations A Connected to fused power source B Pressure relief valve Not included required for each outlet user supplied See Parts page 45 C Series progressive divider valves Divider Installations D To lube points FIG 3 A B C D ...

Page 10: ... Inlet D G3 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 quick disconnect N Fill Manifold P Fill Manifold Outlet Q Fill Manifold Vent Port R Pressure Gauge S Pressure Regulator and Gauge T Pressure Relief Knob To relieve the stall pressure in the fil...

Page 11: ...es not stall dead head there is a leak in the system Key A G3 Pump B Auto Fill Shut Off Valve C Auto Fill Inlet D G3 Reservoir E Remote Fill Reservoir F Remote Fill Pump H Relief Valve J Supply Hose user supplied L Drain Tube L1 Option To reservoir L2 Option To overflow container S Pressure Regulator and Gauge U Pressure Relief Valve V Quick Disconnect W Overflow Container Y Supply Hose Pressure R...

Page 12: ...led 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 See table below for bracket information In high vibration environments additional isola tion at mounting point is necessary See table below AC pumps...

Page 13: ...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 con nector does not exit the unit in the UP direction Use a corrosion preventative electrical grease on all contacts The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause ...

Page 14: ... 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 Illumination via 5 wire CPC power cable Tri Color Remote Illumination M12 Connector Unit in OFF Mode Off Off Unit in ON Mode On Green Warning Condition Toggles On and Off once per second Yellow Fault Condition ...

Page 15: ... Related Wire Color FIG 6 Power DIN DC 15 Foot Pin and Related Wire Color FIG 7 Pin Pin Name Color 1 Line Black 2 Neutral White 3 Not Used Not Used 4 Ground Green FIG 6 Pin Pin Name Color 1 VDC Black 2 VDC White 3 Not Used Not Used 4 Not Used Green FIG 7 ...

Page 16: ...d 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 kits Pin and Related Wire Color FIG 9 Pin Pin Name Color 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 FIG 8 Pin Pin Name Color 1 Not Used Not Used 2 VDC Bla...

Page 17: ...leaning checking or servicing the equipment FIG 10 NOTICE Do not attach unsupported equipment to auxiliary fit tings such as fill ports and pump element Attaching unsupported equipment to these fitting can result in irreparable housing damage Always use two wrenches working in opposite directions when connecting anything to pump ele ment or auxiliary fittings See FIG 10 for an exam ple Torque pump...

Page 18: ...ng the ON time of the pump will allow for con trol of the output volume Use these volume adjustments as a starting point and adjust as necessary to ensure desired lubrica tion dispense Tighten pump element fitting Torque fitting to 50 in lbs 5 6 N m Loading Grease To ensure optimal performance from the G3 Only use NLGI 000 2 greases appropriate for your application automatic dispensing and the equ...

Page 19: ...uipment NOTE If battery disconnect is not available remove the power cord FIG 15 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 Turn the lid counterclockwise to remove 4 Place the lid in a clean area to avoid debris getting into the inside of the lid or threads 5 Fill the reservoir with new clean g...

Page 20: ...ton 3 Fill reservoir with grease until seal of follower plate breaches the vent hole FIG 16 and the majority of air is expelled from the reservoir NOTE Vent port located in rear of reservoir should not be used as an overfill port indicator 4 Remove fill hose Changing Greases When changing greases always use compatible fluids or greases NOTICE Any debris or dirt accidentally introduced into the res...

Page 21: ...and hold the Pressure Relief Knob T long enough to relieve line pressure between Fill Mani fold N and Auto Fill Shut Off Valve B 2 Verify the Auto Fill Shut Off B pin is down indicat ing it is reset FIG 17 3 Remove yellow Dust Cover from Fill Coupler M NOTICE Care must be used when filling the reservoir using a pneumatic or electric transfer pump to not pressur ize and break the reservoir The remo...

Page 22: ...over Fill Coupler M Remote Fill without Remote Fill Manifold The reference letters used in the following instructions refer to the Typical Installation diagram page 11 1 A supply hose pressure relief valve Y and overflow container W for collecting excess fluid that drains during pressure relief must be installed in an easily accessible location between the remote filling sta tion pump F and the Au...

Page 23: ...ll pressure has been relieved 6 Disconnect the supply hose J from Quick Connect V Fill Oil Unit Only use oil appropriate for your application auto matic dispensing and the equipment s operating temperature Consult with machine and lube manu facturer for details Do not overfill FIG 21 Do not operate G3 without reservoir attached Only use oils with viscosity at least 40 cSt 1 Remove fill cap a 2 Pou...

Page 24: ...lowed to run dry 1 Loosen pump element fitting FIG 22 NOTE When loosening pump element fitting do NOT loosen pump element Loosening pump element will change the output volume 2 Only run pump until air is no longer dispensed with the lubricant coming out of element fitting FIG 23 3 Tighten pump element fitting using two wrenches working in opposite directions FIG 22 FIG 22 FIG 23 ...

Page 25: ...Quick Setup Guide 332298J 25 Quick Setup Guide ...

Page 26: ...hen a fault warning event occurs during a run cycle See page 38 for a complete description of these alarm scenarios LOCK ICON LED next to icon lights indicating PIN is required to enter setup In SETUP MODE LED lights when setting up the PRELUBE LED next to icon lights indicat ing Prelube function is en abled LEFT DIRECTION ARROW RESET In SETUP MODE moves cursor in display one field to the left In ...

Page 27: ...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 Progr...

Page 28: ... 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 all the programmed ON Time information is saved The G3 automatically switches to the OFF Time SETUP MODE OFF Time The LED next to the clock in the OFF field l...

Page 29: ...s 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 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 immedi ately Delaying the prelube functi...

Page 30: ...ate 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 behavior of the alarm out put in a fault from either toggling once every second or steady on Firmware 6 02 and later A8 4 Digit Hour Off Time Changes maximum OFF time Default OFF This function changes OFF ...

Page 31: ... and exit Advanced Setup Entering Advanced Setup Press the UP ARROW button for 10 sec onds If the G3 was previously set up to require a PIN Code the LED next to the LOCK ICON lights indi cating 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 num...

Page 32: ...o 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 all the programmed ON T...

Page 33: ...econd 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 A8 4 Digit Hour OFF Time Changes the OFF time from HH MM to HHHH Allows for a maximum of 9999 hours of OFF time OFF LED illuminates 1 The default OFF dis plays 2 Press the UP or DOWN ARROW button to change OFF to ON on the display to...

Page 34: ...fault Low Level ON LED illuminates FIG 29 1 The default OFF is displayed The alarm output will toggle once a second 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 button A11 Warning Off Through Alarm Relay This function changes the behavior of the alarm output in a warning condition to always off Fault and Warnin...

Page 35: ...ult 0001 is displayed When Prelube is on it will run one 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 sequences 3 Press the ENTER button to exit Advanced Programming after the last digit of the pre lube sequence is displayed A13 MM SS OFF Time This ...

Page 36: ...p turns the pump on and it runs for the programmed ON Time cycle FIG 34 Notice the ON Time LED is now illuminated on the display The example shown in FIG 34 shows an ON Time of 8 minutes and 42 seconds before the lubrication cycle ends 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 illu minated FIG 33 This seq...

Page 37: ...Prelube 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 in the OFF field is illuminated FIG 35 The Prelube LED lights FIG 35 The display shows time remaining until lubrica tion cycle begins The example shown in FIG 35 shows 8 minutes and 14 seconds left ...

Page 38: ...icates Solution Low Level 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 lubricant to reservoir After lubricant is added press the RESET but ton to clear the warning Low Level Fault Level of lubricant in reservoir is low and addi tional lubricant nee...

Page 39: ... programmed as intended referencing programming instructions Note the dot designation for hours minutes seconds on the top row of the display Lubricant leaks past seal located on the bottom of the reservoir Reservoir retaining tabs are cracked or broken Replace reservoir Reservoir is being pressurized during filling Ensure vent hole is not plugged If problem persists contact Graco Customer Service...

Page 40: ...l 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 ...

Page 41: ... 15 27 1 45 60 23 57 40a 44 14 1 42 13 18 17 34 36 33 37 41 21 30 15 4 3 31 Follower Plate Models 43 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 2 3 40b 3 Low Level Grease Models Low Level Oil Models Only 66 67 12 ...

Page 42: ... 21 30 15 4 3 31 Follower Plate Models 43 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 2 3 61 40b 3 27 1 45 60 23 57 Low Level Grease Models Only 67 66 Low Level Oil Models 12 13 62 82 83 81 84 85 40c 36 87 88 74 89 45 73 72 Auto Fill Shut Off Models 4L Top Fill Reservoir 75 ...

Page 43: ...plate included in Kits 571044 571046 and 571047 1 36 LABEL brand 1 37 123741 FITTING Zerk grease not included on models 1 40a 24E984 RESERVOIR 2 Liter grease included in Kit 571042 571069 1 40b 16G021 RESERVOIR 2 Liter oil included in Kit 571179 1 40a 577005 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 G3 A...

Page 44: ...g diagram page 16 1 Ref Part Description Qty Kit No Description Manual Number 571026 KIT output union 3 pump 3A0523 571063 KIT output union 2 pump 571028 KIT return to reservoir NPT includes pressure relief valve 16C807 3A0525 571071 KIT return to reservoir BSPP includes pressure relief valve 16C807 571030 KIT remote manual run 12 volt DC 3A0528 571031 KIT remote manual run 24 volt DC 571032 KIT r...

Page 45: ...anjo kit p n 571058 Except 16C807 because the banjo is already included in kit 571028 Fuses Reservoir Conversion Kits Part Description Qty 16C807 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 571071 1 563156 VALVE pressure relief 750 psi 5 17 MPa 51 71 bar 1 563157 VALVE pressure relief 1000 psi 6 89 MPa...

Page 46: ...Option 2 See P N 126916 template FIG 36 0 367inch 9 3 mm 2x Ø 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 Ø 0 366 inch 9 3 mm 3 189 inch 81 0 mm 6 378 inch 162 0 mm 3 740 inch 95 0 mm 0 708 inch 18 0 mm Option 1 Option 2 ...

Page 47: ...Reservoir Size 2 4 8 13 16 Liters IP Rating IP69K Sensor Inputs 3 any of pressure or cycle 1 machine count Ambient Temperatures 40 F to 158 F 40 C to 70 C Noise dBa Maximum sound pressure 70dBa Materials of Construction Wetted Parts nylon 6 6 PA amorphous polyamide zinc plated steel carbon steel alloy steel stainless steel nitrile rub ber buna N bronze nickel plated alnico chemically lubricated ac...

Page 48: ...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 warran...

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