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Installation 

14

3A3956D

Refilling Line Requirements

To relieve the stall pressure in the refilling line a pres-
sure relief valve (U) (F

IG

. 1, page 5) or a fill valve (Z) 

(F

IG

. 3, page 7) 

must

 be installed in the system.

Systems without Fill Valve

A pressure relief valve (U) and overflow container (N) for 
collecting excess fluid that drains during pressure relief, 
must be installed in an easily accessible location 
between the remote filling station pump (P) and the 
Auto-Fill Shut Off (S). This pressure relief valve is used 
to relieve pressure in the refilling line and to reset the 
Auto-Fill Shut Off. See Typical Installation, page 5.

A Pressure Relief Kit: 247902 is available from Graco. 
Contact your distributor or Graco Customer Service for 
additional information about this kit.

Systems with Fill Valve (Z)

Install the fill valve (Z) in an easily accessible location 
between the remote fill station pump (P) and Auto-Fill 
Shut Off Valve (S). See Typical Installation, page 7.

The fill valve is used to relieve pressure in the refilling 
line and to reset the Auto-Fill Shut Off. See the Fill Valve 
instruction manual 333393. Graco fill valve, part no. 
77X542 is available. Contact your local Graco distribu-
tor.

Refilling Pump (P) Requirements

Low Level Sensor (T)

When grease is present the LED is green. When the 
lubricant level in the reservoir reaches approximately 
30% (low level), the LED turns to an amber color. (See 
F

IG

. 11 and the Table below). 

NOTE:

 

At 30% capacity, the amber low level signals the 
tank is reaching a point where the operator should 
refill the tank. There is still lubricant in the tank and 
immediate shutdown is not required. 

If your are using a GLC2200 (part number 24N468, 
Series F or later only), the system will enter a low 
level warning condition (LL03) after the switch input 
is closed for more than 1 second. The pump contin-
ues to operate.

Keep the sensor protective cover (11b, page 19
installed to prevent sensor damage.

Low Level Sensor Wiring instructions begin on page 15.

NOTE:

 Graco GLC2200 (part number 24N468, Series F 

or later only) can be used to run the pump and monitor 
the low level. Refer to F

IG

. 13 for Low Level Sensor wir-

ing in systems controlled with a GLC2200. A Low Level 
Sensor cable (part number 129072) and a GLC2200 
Wiring Harness (part number 24P314) are required.

The remote filling station pump stalls (dead-heads) 
when the reservoir is full, causing the supply system 
pressure to rise to the maximum output pressure
of the filling station pump. To help prevent equipment 
damage or serious injury caused by pressurized 
fluid, such as skin injection or injury from splashing 
fluid, always use a remote filling station pump with a 
maximum output pressure of 5000 psi (34 MPa, 
344.7 bar) and use a refill line with a  pressure rating 
equal to or greater than the refill pump. 

Condition

LED 

COLOR

Out 2 (Pin #2)

(See F

IG

. 13, page 15)

Grease Present

Green

0 VDC

No Grease 
Present

Amber

24 VDC

F

IG

. 11

LED Light

Cover

Summary of Contents for Dyna-Star HP 77X202

Page 1: ...be in tube vent valve auto fill shutoff low level 60 lb or 90 lb reservoir 3500 psi 24 1 MPa 241 bar Maximum Working Pressure 5000 psi 34 MPa 344 7 bar Maximum Refilling Inlet Pres sure Related Manual...

Page 2: ...LED E 12 Pump Control Operation 12 Current Control and Flow Motor Control Settings 12 Current and Flow Control Adjustment 12 Reservoir Mounting 13 Pump B 13 Pump Module Operation 13 Inlet and Outlet C...

Page 3: ...ork 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 Use only groun...

Page 4: ...re 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 ov...

Page 5: ...s full If the pump does not stall dead head there is a leak in the system Key A Lubricant outlet connection marked with an 0 B Pump C Ignition switch C1 Fuse D High pressure lubricant supply lines E I...

Page 6: ...system to suit your needs Key A Lubricant output connection marked with an 0 B Pump C Ignition switch D High pressure lubricant supply lines E Primary metering device F Lubrication controller G Fill p...

Page 7: ...Pump remote filling station R Reservoir remote filling station V Supply Hose W Pressure Relief Line Y Instruction Label Z Fill Valveu Z1 Pressure Relief Knob AA Refilling Line BB Filter NOTE The compo...

Page 8: ...th Graco Wire Harness 77X546 Also see pages 10 and 11 for connection details when a customer user supplied wiring harness is used This equipment stays pressurized until pressure is manually relieved T...

Page 9: ...Installation 3A3956D 9 Pump Connection with Graco Wiring Harness 77X546 Wire Connection Table FIG 5 See FIG 6 Pin Wire Color Connection 1 Orange Signal 2 Black Power 4 Red Power 5 Blue Signal FIG 6...

Page 10: ...24 VDC With Signal Input A Vent Valve is only used in an injector based system 24 VDC With External Relay A Vent Valve is only used in an injector based system FIG 7 Pump control switch shown in signa...

Page 11: ...nter 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 SI...

Page 12: ...rent Control knob G governs pump speed which in turn governs flow The Current setting has precedence over the Flow Rate setting You may be limited in achievable Flow Rate by the Current setting Turn k...

Page 13: ...tion controller F terminates the signal to the pump B and power to the vent valve L 4 The vent valve L opens 5 Pressure in the supply line D is relieved back into the reservoir resetting all injectors...

Page 14: ...l the LED turns to an amber color See FIG 11 and the Table below NOTE At 30 capacity the amber low level signals the tank is reaching a point where the operator should refill the tank There is still l...

Page 15: ...Installation 3A3956D 15 Low Level Sensor Wiring with GLC2200 Lube Controller FIG 12 FIG 13 FIG 14 Pin Connector 6LC 4400...

Page 16: ...ease is added to the reservoir it pushes the dia phragm 5b page 22 up to the top of the reservoir The diaphragm then pushes the valve pin and closes the inlet fluid path When the fluid refilling path...

Page 17: ...ve bv when all pressure has been relieved NOTE The pin may not drop and the Auto Fill Shut Off may not reset because the tank is full However when the pump begins using the grease the pin resets The p...

Page 18: ...is down indicat ing it is reset FIG 19 3 Remove yellow dust cover Z2 from fill coupler Z3 FIG 18 4 Connect refilling line AA between the remote filling stations pump P and fill coupler Z3 port marked...

Page 19: ...te filling station pump P and fill valve Z NOTE The length of time it takes to vent varies depend ing on the system design and installation In some installations it may be necessary to repeat Step b t...

Page 20: ...ther J Reservoir K overfilled because Auto Fill Shut Off S did not shut the refilling line D Replace the Auto Fill Shut Off dia phragm 5b and Auto Fill Shut Off valve 5a Refer to manual 332518 Refilli...

Page 21: ...mber tank has no grease check wiring between sensor and alarm Check sensor LED If there is no light check sensor wiring to verify there is power to the sensor Pressure switch malfunction Check pressur...

Page 22: ...42 GASKET pump 1 3l 104572 WASHER lock spring 4 5 77X521 VALVE auto fill shut off see instruction manual 332518 1 5a VALVE auto shut off 1 5b DIAPHRAGM assembly 1 5c TUBE vent valve 1 5d FITTING conne...

Page 23: ...p wetted parts See Dyna Star HP and HF Pump manual 332514 Reservoir wetted parts steel buna n rubber Vent valve wetted parts See Dyna Star HP and HF Vent Valve Kit manual 332519 Sound data See Dyna St...

Page 24: ...ls US inch Metric cm US inch Metric cm A 30 5 77 47 38 0 96 52 B 14 5 36 83 14 5 36 83 C 19 4 49 28 27 0 68 6 D six 7 16 inch hole 13 7 8 inch bolt circle six 7 16 inch hole 13 7 8 inch bolt circle E...

Page 25: ...Notes 3A3956D 25 Notes...

Page 26: ...n 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 WARRA...

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