Graco G-Mini 25R800 Instructions Manual Download Page 28

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Troubleshooting

3A6714C

Troubleshooting

Pressure Relief Procedure

, page 15,

before checking or repairing.

Problem

Cause

Solution

Unit does not power on.

Incorrect/loose wiring

Refer to

Installation

instructions,

page 6.

Tripped external fuse due to internal
component failure.

Contact Graco Customer Service.

Tripped external fuse from using
grease with an inadequate
temperature rating in a cold
environment.

Replace lubricant with a lubricant
rated for environmental conditions
and application.

Replace fuse.

Lubricant leaks past the seal located
on the bottom of the reservoir.

Seal was not installed correctly.

Replace seal.

Reservoir is being pressurized
during filling.

Ensure that the vent tube is not
plugged.

If the problem persists, contact
Graco Customer Service or your
local Graco distributor for
assistance.

The external controller is
functioning, but the unit is not
pumping during the ON cycle.

Motor failure.

Replace the motor.

The follower plate is not moving
downward.

Air is trapped in the reservoir
between the follower plate and the
lubricant.

Add grease following the

Load

Grease

instructions, page 16.

Purge any air from the reservoir.

After wiring and installing the
equipment, the pump is not working.

The pump is wired incorrectly.

Rewire the pump following

Wiring

and Installation Diagrams

, page 9.

Summary of Contents for G-Mini 25R800

Page 1: ...ssional use only Not approved for use in explosive atmospheres or hazardous classified locations Models page 3 4061 psi 28 MPa 280 bar Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual before using the equipment Save these instructions ...

Page 2: ...Pressure Relief Valves 15 Set Pump Outlet Volume 16 Load Grease 16 Change Greases 17 Priming 18 Non Controller Operation 19 Low Level Output Option 19 Controller Operation 20 RUN MODE 21 SETUP MODE 21 ON TIME Configuration Minutes 21 ON TIME Configuration Cycles 22 OFF TIME Configuration Min Hrs 22 ADVANCED PROGRAMMING 23 Advanced Programming Menu Descriptions 23 Alerts and Alarms 26 Alerts 26 Ala...

Page 3: ...CPC X M12 1 25R804 X X X CPC X M12 1 X 25R805 X X X CPC X M12 2 X 25R806 X X X CPC X M12 1 X 25R807 X X X CPC X 1 25R808 X X X CPC X M12 1 25R809 X X X CPC X 1 25R810 X X X CPC X M12 1 25R820 X X X DIN X 1 25R821 X X X DIN X M12 1 25R822 X X X DIN X 1 25R823 X X X DIN X M12 1 25R824 X X X DIN X M12 1 X 25R825 X X X DIN X M12 2 X 25R826 X X X DIN X M12 1 X 25R827 X X X DIN X 1 25R828 X X X DIN X M1...

Page 4: ...tely 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 Specifications in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Specifi...

Page 5: ...solvent manufacturer for information and recommendations about compatibility 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 Equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all powe...

Page 6: ...voir B Venting Tube C Follower Plate D Pump Element E Zerk Inlet Fill Fitting F Cycle Indicator Connector Controller model only G CPC Connector H Controller J Return to Reservoir V DIN Connector Power W DIN Connector Low level Manual run button FIG 1 D A B C F G E H J J V W ...

Page 7: ...uired for each outlet See Pressure Relief Valves page 15 M Proximity switch cable N Series progressive divider valves Divider Installation P Connection to lube points R Proximity switch see page 14 S Direct Mount CSP Bracket see page 8 T Direct Mount CSP Hose see page 8 U CSP valves X Universal Bracket see page 8 User Supplied FIG 2 K R P N M L X FIG 3 R S L K T U ...

Page 8: ...ious injury including skin injection and amputa tion This device has an automatic timer that activates the pump lubrication system when power is connected or when exiting the programming function Before you install the lubrication pump or remove it from the sys tem disconnect and isolate all power supplies and relieve all pressure Part No Description 26C826 Universal Bracket fastener included 26C8...

Page 9: ...ll DC models To avoid equipment damage Never operate pump DC models without a fuse installed A fuse of the correct amperage must be installed in line with the power entry to the system Fuse Value Graco Kit No Applicable Model 10A 26C916 25R802 25R803 25R806 25R809 25R810 25R822 25R823 25R826 25R829 25R730 5A 26C917 25R800 25R807 25R820 25R827 7 5A 571039 25R801 25R804 25R805 25R808 25R821 25R824 2...

Page 10: ...Power CPC DC 5 Wire Controller Power Cable CPC DC Part No 127780 15 ft 4 5 m 127781 20 ft 6 1 m 127782 30 ft 9 1 m Pin Out 1 Not Used Not Used 2 VDC Black 3 VDC Red 4 Low Level White 5 Low Level Orange 6 Not Used Not Used 7 Not Used Green FIG 7 1 Not Used Not Used 2 VDC Black 3 VDC Red 4 LED White 5 Button Orange 6 Not Used Not Used 7 LED Green FIG 8 ...

Page 11: ... 11 Power CPC DC 3 Wire Non Controller Power Cable CPC DC Part No 127783 15 ft 4 5 m Pin Out 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 Not Used FIG 9 ...

Page 12: ...N DC 15 ft Power Cable Part No 16U790 Pin Out Low Level DIN DC See Technical Specifications page 36 for ratings Pin Out 1 VDC Black 2 VDC White 3 Not Used Not Used 4 Not Used Green FIG 10 1 LL N O 2 LL Com 3 Not Used 4 Not Used FIG 11 ...

Page 13: ...4C 13 Divider Valve Indicator Cycle Inputs M12 See Technical Specifications page 36 for ratings Part No 124333 Cable Pin Out M12 for 5 m Cable Wire Colors FIG 13 FIG 12 Item No Color 1 Brown 2 White 3 Blue 4 Black FIG 13 ...

Page 14: ...e Technical Specifications page 36 for ratings Pin Out Proximity Switch NOTE Reference ILE buyer s guide for appropriate PNP proximity switches and cables Part No Description 25C981 Manual Run Button 12V 25C982 Manual Run Button 24V 1 LED 2 LED 3 Button 4 Not Used FIG 14 ...

Page 15: ...om Graco See Pressure Relief Valves page 15 Pressure Relief Valves 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 FIG 15 NOTICE Do not attach unsuppor...

Page 16: ...al conditions such as lubricant temperature and back pressure from downstream connections Use the volume adjustment process in conjunction with setting the ON time of the pump to control the output volume The volume adjustment process should be used as a starting point for dispensing the desired lubrication volume Load Grease To ensure optimal performance from the pump Use only NLGI 000 2 greases ...

Page 17: ...ling to prevent air pockets from forming in the grease For models using an external controller start the pump operation following the controller instructions 3 Fill the reservoir with NLGI grease to the MAX line FIG 18 NOTE The venting tube B should not be used as an overfill indicator FIG 18 4 Remove the fill hose Change Greases Always use compatible grease when changing grease FIG 17 E FIG 18 B ...

Page 18: ...he pump element fitting FIG 19 NOTE When loosening the pump element fitting do not loosen the pump element Loosening the pump element changes the output volume and causes leakage 2 Only run the pump until air is no longer dispensed with the lubricant out of element fitting FIG 20 3 Tighten the pump element fitting using two wrenches working in opposite directions FIG 21 FIG 19 FIG 20 FIG 21 ...

Page 19: ...lternative ON OFF times are required contact Graco Cus tomer Service for assistance Low Level Output Option Models 25R800 25R802 25R807 and 25R809 Pumps without controllers include a Low Level Output Option The low level signal is monitored across PINS 4 and 5 For the locations and wiring information for PINS 4 and 5 see the Wiring and Installation Diagrams page 9 Model 25R820 25R822 25R827 and 25...

Page 20: ...display while the controller is in OFF TIME MODE A soft ware error occurring when the controller is operating in the OFF TIME MODE will also activate the alarm LED MANUAL RUN ENTER In SETUP MODE press this button to save the entry move the cursor in the display one field to the right or to the next setup step In RUN MODE press this button to start a manual run cycle UP and DOWN ARROWS Hold both th...

Page 21: ...rt and Alarm Scenarios page 27 for full descrip tions SETUP MODE Press both the UP and DOWN arrow buttons together for 3 seconds to enter SETUP MODE The first digit on the display begins to blink This indicates SETUP MODE After entering SETUP Mode if no activity is detected after 60 seconds a timeout occurs and the controller resumes in RUN MODE ON TIME Configuration Minutes The first configuratio...

Page 22: ...r the cycle count to be config ured 2 Press the UP or DOWN arrows to select the first digit 3 Press the ENTER button to save the selection After the ENTER button is pressed the second digit begins to blink The ON LED remains lighted This confirms that the second digit for ON TIME is being con figured in Minutes MM 4 Press the UP or DOWN arrows to select the sec ond digit 5 Press the ENTER button t...

Page 23: ...gs After entering ADVANCED PROGRAMMING if no activ ity is detected for 60 seconds a timeout occurs and the controller resumes RUN MODE Press the ENTER button to advance to the configurable portion of the specific settings 1 Press the UP or DOWN arrows to configure the selection For ON or OFF selection ON UP arrow OFF DOWN arrow 2 After completing configuration press the ENTER button to save and pr...

Page 24: ...ring a PIN Code in the Controller After the controller is configured for PIN entry to access SETUP MODE 1 Follow Steps 1 and 2 of ADVANCED PROGRAM MING page 23 2 Pn appears on the display 3 Press the ENTER button to advance the display 4 The first digit on the display begins to blink This confirms that the controller is ready for the first number of the PIN Code to be entered 5 Press the UP or Dow...

Page 25: ...ow Level Power Cycle Retry When set to ON the Low Level Auto Clear feature allows the controller to attempt to automatically clear a Low Level Alarm during the power cycle This feature is only used when a controller has the power removed while in a Low Level Alarm state The Low Level Auto Clear is an OF OFF or On ON selection OF OFF default Upon power cycle the control ler will remain in its curre...

Page 26: ...cycle to stop Alarms can trigger immediately or can be the result of an escalated Alert Alarms must be cleared immediately A red LED illuminates under ALARM on the display when an Alarm occurs See the Alert and Alarm Scenarios table on page 27 for a descrip tion of Alarms that could occur When an Alarm is triggered any active lubrication cycle will be terminated The display begins to count up to i...

Page 27: ...e An alert will auto clear An alarm must be reset by pressing and holding the Cancel Button for 4 sec onds Over Current The measured motor current is above the maximum operating level The motor turns off and a new lube cycle is not allowed to be initiated Check to make sure that the system is operating correctly A blocked line could create excessive motor current Examine the pump to verify it is r...

Page 28: ... the bottom of the reservoir Seal was not installed correctly Replace seal Reservoir is being pressurized during filling Ensure that the vent tube is not plugged If the problem persists contact Graco Customer Service or your local Graco distributor for assistance The external controller is functioning but the unit is not pumping during the ON cycle Motor failure Replace the motor The follower plat...

Page 29: ... Fill Fittings Keep all of the fittings clean using a clean dry cloth Dirt and or debris can damage the pump and or the lubrication system Daily Pump Unit and Reservoir Keep pump unit and reservoir clean using a clean dry cloth Monthly External Wiring Harness Verify external harnesses are secure ...

Page 30: ... codes and regulations Kit No Description 26C943 Kit Replacement Reservoir 1L 26C945 Kit Replacement Reservoir 0 5L 26C944 Kit Replacement Reservoir Follower Plate 1L 26C946 Kit Replacement Reservoir Follower Plate 0 5L Kit No Description 26C947 Standard G Mini Pump Element Output 3 cc min 26C948 Alternative G Mini Pump Element Output 1 5 cc min ...

Page 31: ...in lb 2 6 N m 3 Torque to 13 in lb 1 5 N m 1 Torque to 65 in lb 7 3 N m 2 1a 1b 2 3a 3b 4a 4b 46 6 12 11 19 20 22 23 24 25a 25b 28 32a 32b 33 34 38 39 41a 41b 42 43 44 45 19 19 1 1 2 3 3 4 50 Torque to 7 in lb 0 8 N m 4 63a 63b 65 64 4 66 ...

Page 32: ... 20 Seal Reservoir included in kits 26C943 26C944 26C945 26C946 1 22 Pump element assy included in kits 26C947 26C948 Model 25R805 25R825 2 Pump element assy included in kits 26C947 26C948 Model 25R800 25R801 25R802 25R803 25R804 25R806 25R807 25R808 25R809 25R810 25R820 25R821 25R822 25R823 25R824 25R825 25R826 25R827 25R828 25R829 25R830 1 23 100721 Plug 1 4 npt HEX socket 2 24 555888 Nipple 1 2...

Page 33: ...820 25R821 25R822 25R823 25R824 25R826 25R827 25R828 25R829 25R830 1 50 16A579 Label Warning 1 63a DIN connector Low Level Model 25R820 25R822 25R827 25R829 1 63b DIN connector Manual Run Button Model 25R821 25R823 25R824 25R825 25R826 25R828 25R830 1 64 DIN connector Power Input 1 65 Screw Self Tap Model 25R820 25R830 8 66 Cap Model 25R820 25R830 2 Ref Part Description Qty ...

Page 34: ...Dimensions 34 3A6714C Dimensions Model Height A Width B Depth C Inches cm Inches cm Inches cm 0 5L 10 9 27 7 6 97 17 7 6 57 16 7 1L 12 2 31 0 6 97 17 7 6 57 16 7 ...

Page 35: ...Dimensions 3A6714C 35 Pump Mount Universal Bracket Mount CSP Valve Bracket Mount ...

Page 36: ... 24 VDC Outputs Low Level Contact Rating 100 W maximum Switch Rating 200 VDC maximum Switching Current 0 5 A maximum Carry Current 1 2 A maximum Outputs Manual Run Button Pump Voltage 12 VDC 11 mA at 12 VDC Pump Voltage 24 VDC 22 mA at 24 VDC Pump Output 3 0 cc minute at room temperature with 4061 psi 28 MPa 280 bar back pressure Pump Outlet 1 4 in NPT female Reservoir Size 0 5 L 1 0 L IP Rating I...

Page 37: ...A6714C 37 California Proposition 65 WARNING This product can expose you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm For more information go to www P65warnings ca gov ...

Page 38: ...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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Graco G-Mini 25R800, Instructions Manual

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