Graco G3-G-12MX-2L0L00-10C00000 Instruction Manual Download

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332305G

Instructions

G3 Max Automatic
Lubrication Pump

For dispensing of 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 locations.

Part Nos., page 3

5100 psi (35.1 MPa, 351.6 bar) Pump Output Pressure
5000 psi (34.4 MPa, 344.7 bar) Maximum Working Pressure - Auto-Fill Shut Off

Important Safety Instructions

Read all warnings and instructions in this
manual. Save all instructions.

Conforms to ANSI/UL 73
Certified to CAN/CSA
Std. 22.2 No 68-09

3132066

Summary of Contents for G3-G-12MX-2L0L00-10C00000

Page 1: ...oved for use in explosive atmospheres or hazardous locations Part Nos page 3 5100 psi 35 1 MPa 351 6 bar Pump Output Pressure 5000 psi 34 4 MPa 344 7 bar Maximum Working Pressure Auto Fill Shut Off Important Safety Instructions Read all warnings and instructions in this manual Save all instructions Conforms to ANSI UL 73 Certified to CAN CSA Std 22 2 No 68 09 3132066 ...

Page 2: ...tup Guide 28 Max Model Setup 29 Control Panel Overview 29 Programming the Max Model 30 Checking the Firmware Version 30 PUMP OFF REST Setup 35 DMS Models Only 38 Storing Pump Program Settings to the Flash Drive 38 Uploading Pump Program Settings to the Pump 39 Operation Data Log 40 System Event Log 40 Error Log 41 Functional Summary 43 Technical Summary 45 Advanced Programming 46 Run Mode 53 Time ...

Page 3: ...4MX 2LFL00 UDMVA1R2 96G122 G3 A ACMX 2L0L00 1DMVA2R3 96G125 G3 G ACMX 2L0L00 UDMVA1R2 96G132 G3 G ACMX 2LFL00 UDMVA1R2 96G174 G3 A ACMX 2L0L00 UDMVA1R2 96G178 G3 G 24MX 2L0L00 0D00A100 96G190 G3 A 24MX 2L0L00 UDMVA1R2 96G206 G3 G 24MX 24L0L07 0D00A000 Part Model Numbers 96G088 G3 G 24MX 4L0L00 10CV00R0 96G090 G3 G 24MX 4LFL00 10CV00R0 96G092 G3 G ACMX 4L0L00 1D0V0000 96G094 G3 G ACMX 4LFL00 1D0V00...

Page 4: ...L05 10CV0000 96G158 G3 G 24MX 8L0L05 U0CV0100 96G176 G3 A ACMX 8L0L00 UDMVA1R2 96G177 G3 G 24MX 8L0L05 00C0010M 96G186 G3 A 12MX 8L0L05 U0C0010M 96G216 G3 G 24MX 8L0L08 10CV0000 96G191 G3 G 24MX 8L0L05 10CV02M3 96G195 G3 A 24MX 8L0L05 U0C0010M 96G197 G3 G ACMX 8LFL00 1DMVA2R3 96G209 G3 G ACMX 8LAL00 1DV00000 96G215 G3 G 24MX 8LAL05 10CV0000 96G216 G3 G 24MX 8L0L08 10CV00000 Part Model Numbers 96G1...

Page 5: ...l Code cc Reservoir Capacity Liters 2L 2 Liters 4L 4 Liters 8L 8 Liters 12 12 Liters 16 16 Liters Code d Follower Plate Installed F Follower Plate Installed 0 No Follower Plate A Auto Fill Shut Off Code e Low Level Option L Low Level with Controller 0 No Low Level monitoring Code ff Options 00 No Options 03 Powered Alarm Contact 05 5 Pin CPC power cable 07 No Power Cord 08 Normally open vent valve...

Page 6: ...d 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 r...

Page 7: ... CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail which could cause serious injury or property damage Use only compatible water based solvents to clean plastic structural or pressure containing parts See Technical Data in this and all other equipment instruction manuals Read fluid and solvent manufacturer s SDSs and recommendations MOVING PARTS HAZARD Moving p...

Page 8: ...ated in a tilted or inverted position for any period of time you must use a model that includes a fol lower plate otherwise the G3 must be mounted upright Refer to your model number to confirm if a follower plate was installed on your pump See page 5 Understanding the Model Number to identify this character in your model number Use the three fasteners included to secure the G3 to the mounting surf...

Page 9: ...ncluded not shown Available from Graco See Parts page 76 H Control Panel I Power Sensor Panel both sides only one side shown J Part Number Model Number example only shown see pages 5 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 grease mo...

Page 10: ...s page 75 C Cycle indicator sensor cable Divider Installations Pressure switch cable Injector Installations D Series progressive divider valves Divider Installations Injectors Injector Installations E To lube points F Proximity Switch Divider Installations Pressure switch Injector Installations G Vent valve Not included available from Graco See Parts beginning on page 74 H Return to reservoir FIG ...

Page 11: ... 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 12: ...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 13: ...ng 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 cau...

Page 14: ...ector Unit in OFF Mode Deactivated off Off Off Unit in ON Mode Deactivated off On Green Warning Condition Deactivated off Toggles On and Off once per second Yellow Low Level Indication A9 OFF See Warning or Fault Con dition Toggles On and Off once per second See Warning or Fault Con dition Fault Condition Advanced Programming A7 OFF Toggles On and Off once per second Toggles On and Off once per se...

Page 15: ...ded in this manual Output Tied to Common No Faults or Warnings Fault Advanced Programming A7 OFF Fault Advanced Programming Setting A7 ON N O N C N O N C 1 second N O N C Diagram Symbol Page Power DIN AC 16 Power DIN DC 16 Power CPC DC 17 Inputs M12 18 Vent Valve Outputs 19 Alarm Outputs 19 Illuminated Manual Run Input Kits 571030 571031 571032 571033 ...

Page 16: ...Pin and Related Wire Color FIG 7 Power DIN DC 15 foot Pin and Related Wire Color FIG 8 Pin Pin Name Color 1 Line Black 2 Neutral White 3 Not Used Not Used 4 Ground Green FIG 7 Pin Pin Name Color 1 VDC Black 2 VDC White 3 Not Used Not Used 4 Not Used Green FIG 8 ...

Page 17: ...n with a 5 wire CPC cable is available from Graco Con tact your local Graco distributor or Graco Customer Ser vice for additional information about these kits Pin and Related Wire Color FIG 10 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 9 Pin Pin Name Color 1 Not Used Not Used 2 VDC Black 3 VDC Red ...

Page 18: ...C Pin Pin Name Wire Color 1 Not Used Not Used 2 VDC Com Black 3 VDC Red 4 Alarm White 5 Manual Orange 6 Not Used Not Used 7 Low Level Warning Green FIG 11 FIG 12 1 SW 2 Not Used 3 SW 4 Signal 3 4 1 2 Sink NPN 2 or 3 wire 1 2 3 4 Source PNP 2 or 3 wire 1 2 3 4 Dry Contacts 1 2 3 4 Example Wiring Diagram Pin out Connector on Housing ...

Page 19: ...Installation 332305G 19 Vent Valve Outputs See Technical Data page 77 for ratings Alarm Outputs DC example shown See Technical Data page 77 for ratings 1 FIG 13 FIG 14 1 ...

Page 20: ...No 124595 5 Pin Eurofast Field Wireable Connector Part No 124300 Field Wireable Pin Out M12 Wire Colors FIG 17 Part No 124594 4 Pin Eurofast Field Wireable Connector Item No Color 1 Brown 2 White 3 Blue 4 Black FIG 15 FIG 16 Item No Color 1 Brown 2 White 3 Blue 4 Black FIG 17 FIG 18 ...

Page 21: ...eaning checking or servicing the equipment FIG 19 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 19 for an exam ple Torque pump ...

Page 22: ...ng the ON time of the pump will allow for control of the output volume Use these volume adjustments as a starting point and adjust as necessary to ensure desired lubrica tion dispense 3 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 eq...

Page 23: ... Models with a follower plate 1 Connect fill hose to inlet fitting D FIG 22 2 For higher viscosity fluids start pump to rotate stir ring paddle during fill to prevent air pockets from forming in grease To start the pump press the manual run button 3 Fill reservoir with grease until seal of follower plate breaches the vent hole FIG 24 and the majority of air is expelled from the reservoir NOTE Vent...

Page 24: ...ut 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 25 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 r...

Page 25: ...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 12 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 26: ... pressure has been relieved 6 Disconnect the supply hose J from Quick Connect V Filling 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 29 Do not operate G3 without reservoir attached Only use oils with viscosity at least 40 cSt 1 Remove fill cap a 2 Po...

Page 27: ...d to run dry 1 Loosen pump element fitting FIG 30 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 31 3 Tighten pump element fitting using two wrenches working in opposite directions FIG 30 FIG 30 FIG 31 ...

Page 28: ...Quick Setup Guide 28 332305G Quick Setup Guide 0 ...

Page 29: ...complete description of these alarm scenarios PIN ICON LED next to icon lights indi cating PIN is required to enter setup In SETUP MODE LED lights when setting up the PIN PRELUBE LED next to icon lights indicat ing LED lights when Prelube function is enabled LEFT DIRECTION ARROW RESET In SETUP MODE moves cursor in display one field to the left In RUN MODE single press clears warning In RUN MODE pr...

Page 30: ...me cycle and the OFF Time restarts counting down the total programmed amount of time It does not resume the countdown from the point where the cycle was interrupted when you entered SETUP MODE Entering Setup Mode Press both the UP and DOWN ARROW buttons together for 3 seconds to enter the SETUP MODE NOTE If the lock LED is lit after entering Setup Mode and four 0000 s are displayed the unit has a ...

Page 31: ...gh the number 0 9 until the number for the current decade is displayed in the field 2 Press the ENTER button to set the decade number The cursor auto matically moves to the next field the year number 3 Use the UP and DOWN arrow but tons to move up and down through the number 0 9 until the number for the current year is displayed in the field 4 Press the ENTER button to set the year number The 3 ch...

Page 32: ...eld to the right blinks and the LED under the MM lights indicating the G3 is ready to program the minutes fields 6 Repeat steps 1 4 to set the minutes MM fields 7 After pressing the ENTER button to set the time the programmed Time information is saved Programming ON Duration OFF C1 C2 C3 or P1 P2 P3 displays identifying the func tion you are program ming Selection of OFF C1 C2 C3 or P1 P2 P3 desig...

Page 33: ...e G3 saves the Cycle information and moves to setting Backup Time page 36 Pressure Control P1 P2 P3 Setup For injector systems monitoring pressure can be used as a way to ensure sufficient pressure has been reached to activate injectors The pump runs building up enough pressure to cause injectors to dispense fluid Pressure continues to build to a pre set maximum activating the user supplier pres s...

Page 34: ...f display blinks indicating the device is ready for you to begin programming Programming Backup Time NOTE When programming a time of less than 10 min utes you must program the leading zero in the first num ber field and press the ENTER button to save the zero selection 1 To set the ON Time use the UP or DOWN ARROW button to scroll through numerals 0 to 5 until the desired number appears in the fir...

Page 35: ...onds 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 PUMP OFF REST Setup After setting the parameters for either Cycle C1 C2 or C3 or Pressure P1 P2 or P3 ON modes the OFF or pump rest cycle must be set up There are 3 ways to con...

Page 36: ...rst number field and press the ENTER button to save the zero selection 1 To set the Backup Time use the UP or DOWN ARROW button to scroll through numerals 0 to 9 until the desired number appears in the first HH hour field 2 Press the ENTER button to lock in the selection The next HH number field to the right flashes indicating it is ready for programming 3 Use the UP or DOWN ARROW button to scroll...

Page 37: ... button to lock in the selection The next number field to the right flashes and the LED lights under MM indicating it is ready to program the minutes fields 5 Repeat steps 1 4 to set the next MM minutes fields 6 After pressing the ENTER button to set the last MM field the OFF Time informa tion is saved Prelube The Prelube function determines operation of the pump when power is applied It can be se...

Page 38: ...Data 1 Plug the USB flash drive into the USB port NOTE The G3 pump stops pumping as soon as the USB flash drive is plugged into it 2 The system automatically begins downloading data to the USB drive 3 data is displayed while the system is downloading files 4 When download is finished done is displayed 5 G3 pump restarts cycle in the OFF mode 6 Remove the USB flash drive Storing Pump Program Settin...

Page 39: ...d in the USB flash drive 7 data is displayed while the unit is uploading the configuration data 8 When upload is finished done is displayed 9 G3 pump restarts cycle in the OFF mode 10 Remove the USB flash drive 11 After the USB flash drive is removed press and hold the UP and DOWN ARROW but tons for 3 seconds to enter the SETUP MODE see Entering Setup Mode page 30 12 In SETUP MODE set the YEAR MON...

Page 40: ...ultiple downloads are done on the same date the existing files will be writ ten over The folder structure is as follows GRACO G3_ DMS_id download date YYYYm mDD EVENTLOG CSV Example GRACO G3_00025 20100911 EVENT LOG CSV Sample System Event Log Example Event Log 1 Pump cycle of a divider valve system with a proximity switch set to detect 5 divider valve cycles G3 System Event Log DMS ID Number 0025...

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