Graco 309098F User's Manual
Contents
1. Ground wire for non mobile installation Hydraulic tank line p Vent valve Vent line P Follower plate optional High pressure hydraulic line W High pressure hydraulic connection Tank hydraulic connection V Ball valve Level Indicator optional z cdomuzzrazcrommoou L N x oU User provided Pressure reducing valve PRV g PRV m Fig 2 6 309098 X Power Supply N optional Mus MP MR Pressure Switch For System Control Remote Alarm Device Light or Horn User provided AA Hydraulic Reservoir Return From Hydraulic 9649B Fig 3 Fig 4 Vent Valve Installation Kit 243170 KEY mmoou Hydraulic control line Vent valve Pump output connection line Pressure relief valve Lubricant output Vent line 9647A Control Module Installation Kit 243501 KEY G Pump tank line H Pump high pressure hydraulic line J Vent valve hydraulic control K Hydraulic tank connection L High pressure hydraulic connection M Pressure reducing valve N Flow control valve P 3 Way solenoid valve R Regulated hydraulic pressure gauge Coil should always be installed with lettering facing out 9648A 309098 7 8 Installation Vent return port 1 2 npt f Pump mounting 343 or 5 16 18 4X Vent valve bracket weld locations Control module 343 or2. 115774 2f 161889 UNION adapter 1 4f 115757 2g 157705 UNION swivel 1 4g 115758 2h 158212 BUSHING 1 4h 115760 2i 115470 UNION union swivel 90 1 4j 115763 2j 162667 ELBOW street pipe 1 Ak 115776 2k 194867 BRACKET vent valve 1 Am 115829 2m 194995 HOSE vent 1 2 in 1 4n 160327 2n 238370 HOSE 2 4p 207648 2p 249063 VALVE vent 1 4q 238370 See manual 309099 4r 802072 2q 156684 UNION adapter 1 5 100214 6 110384 7 101864 8 15M442 Installation kits for custom user provided lubricant reservoirs not shown Description KIT reservoir 90 grease PLUG pipe TEE pipe NUT flanged hex SCREW cap flange head BREATHER GASKET cover PAIL reservoir COVER reservoir PLUG pipe KIT installation control module ADAPTER male MODULE hydraulic control VALVE 3 way solenoid VALVE flow regulating VALVE pressure reducing ADAPTER straight thread ADAPTER straight thread ADAPTER straight thread ADAPTER straight thread HOSE 3 4 X3 4 NPT UNION swivel 90 degree UNION adapter 90 degree UNION adapter 90 degree HOSE coupled 1 ft GAUGE pressure WASHER lock SCREW cap hex hd SCREW cap GASKET pump 309098 Qty 13 ARNDOA a ma aa a a a a CO CI CI COTO CO CTO CRON COO CO COO COS CMI CRs CHEN NOE OMM Technical Data Maximum hydraulic input pressure iis ee ss ee ee ee Ie 3500 psi 241 bar 24 MPa
3. lubricant flow and pressure to operate the injectors and vents the injector system to reset the injectors 4 309098 1 Upon receiving a signal from a 24 volt lubrication controller the 3 way solenoid valve Fig 3 item F opens starting the pump D and closing the vent valve U The pumps builds pressure until the pressure switch in the system sends a signal to the timer ending the cycle or the pump stalls The timer terminates the 24 volt signal to the 3 way solenoid valve F The 3 way solenoid valve F closes stopping the pump and opening the vent valve U The system lubricant pressure bleeds back through the vent valve U into the reservoir P The pressure reducing valve PRV item S and flow control valve FCV item N control the pump output pressure and cycle rate Installation Reservoir Mount reservoir Fig 2 item P on sturdy flat surface with 6 3 8 in diameter bolts Note location of fill port K hydraulic lines and lubricant outlet port G for easy access once installed A WARNING Hydraulic system must depressurized before connecting high pressure hydraulic supply line A CAUTION Hydraulic supply must be 10u filtered or better and supply 0 5 3 0 gpm 1 9 11 4 lpm at 800 psi 3500 psi 55 bar 241 bar 5 5 MPa 24 MPa 1 Readinstruction manual 308156 included before installing this product 2 Install ball valve Fig 2 item AA user
4. Pump wetted parts essc eem rem VR de ED GR Rei bed ok gt e c Ren ew RR e See manual 308156 Vent valve wetted parts iese ee ee ed ee ee ee ee ee emm m See manuals 309099 Reservoir wetted parts sis EE SE SE Ge Ge ee ee Gee erm steel buna n rubber Maximum delivery ii Es ER es ee ee ee 66 oz min 119 in min 1952 cmS min at 3 gom hydraulic flow rate Hydraulic pressure operating range is cee eee eee 800 to 1200 psi 5 5 to 8 MPa 55 to 83 bar Hydraulic flow rate operating range eects 0 5 to 3 0 gpm 1 9 to 11 4 liter min Lubricant outlet pressure range 0 eee eee ees 2500 to 3500 psi 17 to 24 MPa 172 to 241 bar Reservoir overflow port size ete tn tenes 1 2 npt Figure 3 item L Reservoir fill port size eriwer ss EE ee eee nn 1 2 npt Figure 3 item K Hydraulic inlet port size ses EE a a Re ee Re eee 3 8 nps swivel Figure 3 item T Hydraulic tank line size tenets 3 4 nps swivel Figure 3 item X Lubricant outlet port size oe scriere tte teens 1 2 nps swivel Figure 3 item G Grease capacity wo EA tob de atria ivan e RENE EE AE home Wa IE cheated 90 Ib Mounting holes for pump module 0 EE Ee EE Se Ee ee tees Six 7 46 holes on 13 Ja bolt circle Reservoir diameter is HE MEE EER ace De ERG p uk DG DERE ee ge Eg eb ue d atau Pind 12 3 4 324 mm Pubip module height xu ars se den i ware rt UR ey db rtp que AR err se RA e ba DU RE 37 3 4 959 mm
5. 27 34 Nm lubricate o ring with oil before installation 2q Item 4e Torque to 15 20 ft Ibs 20 27 Nm lubricate o ring with oil before installation 3b Item 4f Torque to 68 75 ft Ibs 92 102 Nm lubricate o ring with oil before installation g Item 4g Torque to 22 24 ft Ibs 30 33 Nm lubricate o ring with oil before installation Item 4h Torque to 40 43 ft Ibs 54 58 Nm lubricate o ring with oil before installation amp d C 9652B 309098 Parts List Model 243159 Dynastar Pump Module includes items 1 8 Model 243502 35 Dynastar Pump Module Installation Kit includes items 1 2 4 and 8 Model 243503 120 Dynastar Pump Module Installation Kit includes items 1 2 4 and 8 Model 243504 400 Dynastar Pump Module Installation Kit includes items 1 2 4 and 8 Ref Ref No PartNo Description Qty No Part No 1 224751 PUMP used on Model 243159 3 241486 and Model 243503 1 da 100737 See manual 308156 3b 108126 224912 PUMP 354 Dynastar 1 3c 110996 used on Model 243502 3d 111800 See manual 308156 3e 115254 224752 PUMP 400 Dynastar 1 3f 194868 used on Model 243504 3g 194907 See manual 308156 3h 247448 2 243170 KIT installation vent valve 1 3i 104663 2a 100505 BUSHING pipe 1 4 243501 2b 100840 ELBOW street 1 da 112581 2c 100896 FITTING bushing pipe 1 4b 115746 2d 111801 SCREW cap hex hd 2 4c 115775 2e 115122 VALVE pressure relief 1 4d 115773 see manual 308954 de
6. 5 16 18 2X 18 0 Max 5 0 gt 5 0 7 ST a O O E CO Y E B 3 536 6 875 Q Q Yy 3 536 gt O yV Fig 5 9653A 309098 Operation Pressure Relief Procedure A WARNING INJECTION HAZARD To reduce the risk of serious injury in cluding fluid injection or splashing in the eyes or on the skin always follow the Pressure Relief Procedure whenever you Are instructed to relieve the pressure Shut off the pump Check clean or service any of the system equipment Install or clean the dispensing devices 1 Disable hydraulic supply to pump Fig 2 item D by isolating it it from the high pressure hydraulic supply using ball valve AA 2 Doone of the following e Open the pressure reducing valve to reduce trapped hydraulic pressure or Cycle the timer to open the 3 way solenoid valve to reduce trapped hydraulic pressure Note Gage on control module should read zero pressure after performing this step 3 Disconnect power from Lubrication Controller J A WARNING MOVING PARTS HAZARD Do not insert finger into the overflow port while filling a reservoir equipped with a follower plate Injury or amputation could result Start up Prime Vent Line The first time the reservoir is filled use the vent valve outlet This removes all air from the vent line Fig 2 item V 1 Connect lubricant supply hose from remote fillin
7. Electrical requirements sepes RED Ee rer ea ane ed DATE REA Timed 24 VDC signal Electrical power requirements sesse se ee se ee nti de ke ee tee eee eens 14 7 Watts Filtration hydraulic fluid 2 0 0 0 0 EE Ee ee Ee ee ee ee de ee Re ee ee GR Re ed ee ee ee de ae 10u microns or better Sound pressure 22 ote t eg ER ead Ll i e ER GR x tier lenge 77 dB A Sound pressure reading taken with pump operating at 66 cycles per minute Sound pressure measured per CAGI PNEUROP 1971 Dimensions Hydraulic high pressure inlet 3 8 nps swivel Overflow port 1 2 npt Hydraulic tank 3 4 nps swivel 42 75 in 1086 mm 215 0 in Mounting Diagram eo 381 mm Lubricant outlet 1 2 npt swivel 6x 7 16 holes 13 7 8 bolt circle Fill port 1 2 in npt 9650A 14 309098 Hydraulic Control Module Circuit 243501 Does not include pump and pump valve kit 309098 15 Graco Standard Warranty Graco warrants all eguipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any
8. 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 warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents n
9. INSTRUCTIONS PARTS LIST C 309098F This manual contains important GRACO ENG Le warnings and information Felines when READ AND KEEP FOR REFERENCE quality counts INSTRUCTIONS For Automatic Lubrication Systems Only Provides lubricant flow and pressure to operate a single line parallel automatic lubrication system and vents the system to reset the injectors 5 1 Dynastar Pump Module Part No 243159 Series C Part No 243502 35 Custom Tank Installation Part No 243503 120 Custom Tank Installation Part No 243504 400 Custom Tank Installation 3500 psi 24 MPa 240 bar Maximum Lubricant Outlet Pressure 3500 psi 24 MPa 240 bar Maximum Hydraulic Fluid Input Pressure Hydraulic Vent Valve Kit Part No 243170 Hydraulic Control Module Kit Part No 243501 GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1999 GRACO INC Graco Inc is registered to S EN ISO 9001 A WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury e This equipment is for professional use only Read all instruction manuals tags and labels before you operate this equipment Use the equipment only for its intended purpose If you are not sure call your Graco distributor Do not alter or modify this equipment Use only Graco approved repair parts Check equipment daily Repair or replace worn or damaged parts immediatel
10. NG INJECTION HAZARD Fluid from the dispensing valve leaks or ruptured components can inject fluid into your body and cause extremely serious injury including the need for amputation Fluid splashed in the eyes or on the skin can also cause serious injury Fluid injected into the skin might look like just a cut but it is a serious injury Get immediate surgical attention Do not put your hand or fingers over the end of grease outlet Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure on page 9 if the injector clogs and before you clean or service this equipment Tighten all fluid connections before you operate this equipment Check the hoses tubes and couplings daily Replace worn or damaged parts immediately Do not repair high pressure couplings you must replace the entire hose Fluid hoses must have spring guards on both ends to protect them from rupture caused by kinks or bends near the couplings TOXIC FLUID HAZARD Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin inhaled or swallowed Know the specific hazards of the fluid you are using Store hazardous fluid in an approved container Dispose of hazardous fluid according to all local state and national guidelines Always wear protective eyewear gloves clothing and respirator as recommended by the fluid and solvent manufacturer MOVING PARTS HAZARD um Mov
11. g station pump unit to outlet of vent valve U 2 Remove plug in fill port K located at bottom of reservoir 3 Slowly turn on supply lubricant until lubricant appears in fill port 4 Remove lubricant supply hose from vent valve Fill Reservoir 1 Connect lubricant supply hose from remote filling station pump to fill port Fig 2 item K 2 Connect automatic lube system main supply line G to vent valve U outlet 3 Remove plug from overflow port L 4 Slowly turn on supply lubricant until level of lubri cant reaches overflow port Note For systems with a follower plate fill until the follower plate reaches the overflow port Note Refer to Automatic Lube System Design Guide lines Manual 309015 for instructions on priming re maining system lubricant lines and further operating instructions A WARNING COMPONENT RUPTURE HAZARD GO am The maximum working pressure of each p component in the system may not be the same To reduce the risk of overpressurizing any component in the system be sure you know the maximum working pressure of each component Never exceed the maximum working pressure of the lowest rated component in the system Overpressurizing any component can result in rupture fire explosion property damage and serious injury Regulate hydraulic pressure to the pump so that no fluid line component or accessory is overpressurized 5 Set hydraulic pressure to pump at
12. ig 2 2 Connect the hydraulic tank line Fig 4 item G to the pump hydraulic outlet port 3 Connect the vent valve hydraulic control J con nection to the hydraulic control line Fig 3 item A 4 Connect the pump high pressure hydraulic line Fig 4 item H to the pump hydraulic input port 5 Connect the high pressure hydraulic supply to the high pressure hydraulic supply connection L and the tank lines to the hydraulic tank connection K 6 Connect the 3 way solenoid valve P to the timer Note Coil should always be installed with lettering facing out 309098 5 Typical Installation Installation The installation shown in Figs 2 4 and 5 are only a guide for selecting and installing system components Contact your Graco distributor for assistance in planning a system to suit your needs KEY High pressure hydraulic lines Hydraulic tank line Lubricant output connection Pump module Ignition switch 3 Way solenoid valve High pressure lubricant supply lines ry G 24v x Battery Injector banks Lubrication controller Fill port Overflow port AB Breather C Flow control valve FCV A Controller Capabilities J Low Reservoir Level Switch Level Indicator Reservoir E
13. ing parts such as the air motor piston can pinch or amputate your fingers Do not insert fingers in overflow port when filling reservoir Keep clear of all moving parts when you start or operate the pump Before you service this equipment follow the Pressure Relief Procedure on page 9 to prevent the equipment from starting unexpectedly 309098 3 Unpacking Unpacking the Product The Dynastar pump module was carefully packaged for shipment by Graco When the package arrives perform the following procedure to unpack the units 1 Inspect the shipping box carefully for shipping damage Contact the carrier promptly if damage is discovered 2 Unseal the box and inspect the contents carefully There should not be any damaged parts Compare the packing slip against all items in cluded in the box Any shortages or other inspec tion problems should be reported immediately Store the box and packing materials in a safe place for future use Graco recommends that all packing materials be saved in case the unit needs to be shipped again Pump Module Overview Pump Module Operation Pump Module Operation performs these cycles Pump Module Capabilities The Pump Module provides lubricant flow and pres sure to operate a single line parallel automatic lubrica tion system The module requires a hydraulic power Supply and a timed signal from a lubrication controller Based on these signals the pump module provides
14. lowest pressure needed between 600 psi 41 bar 4 1 MPa and 1200 psi 83 bar 8 MPa to get desired output results between 2500 psi 172 bar 17 MPa and 3500 psi 241 bar 24 MPa Set hydraulic flow rate to pump at lowest flow rate needed to get desired results 7 Read and follow instructions supplied with each system component Note With a primed pump and sufficient hydraulic supply the pump starts when the timer activates the solenoid valve The pump stops when the timer deacti vates the solenoid valve 309098 9 Shut Down 1 For normal system shut down disconnect power to lubricator controller J by turning off the ignition switch and turn off hydraulic supply by closing the ball valve Fig 2 item AA Problem Operation A CAUTION Never allow the pump to run dry of the fluid being pumped A dry pump will quickly accelerate to a high speed possibly damaging pump If your pump accelerates quickly or is running too fast stop the pump immediately and check the fluid supply Troubleshooting Cause Solution System does not build sufficient pressure Pump malfunction Pump turned off too soon Solenoid malfunction Too low or no hydraulic supply Vent valve seal failure Vent valve needle seat failure Reservoir out of grease Broken or leaky supply branch line Injector failure Pressure in tank line too high due to restrictions in tank line or plumbing too small Refer to
15. manual 308156 Increase timer pump on setting Increase hydraulic flow rate to pump Repair or replace Turn pressure up or supply on Replace seal Replace needle and seat Fill reservoir Tighten connections and or replace line s Repair or replace Remove tank line restrictions Use larger plumbing Lubricant dispensed from pres sure relief valve System pressure set too high Decrease hydraulic pressure to pump Pump runs too fast Reservoir out of lubricant Pump cavitation Leak in distribution system Fill reservoir Install a follower plate Repair leak Lubricant coming out of breather Reservoir overfilled Drain lubricant until overflow stops Pump will not start 10 309098 No hydraulic supply Solenoid malfunction No electrical supply to lubrication controller Lubrication controller malfunction Pump malfunction Verify check hydraulic supply Replace solenoid Turn on electrical supply Refer to controller manual 308950 Refer to pump manual 308156 Parts Drawing Pump hydraulic outlet x Pump hydraulic inlet 3a 7 9652B 309098 11 12 Parts Drawing _To pump hydraulic inlet To pump lubricant outlet 2m Item 4a Torque to 40 43 ft lbs 54 58 Nm lubricate o ring with oil before installation Item 4c Torque to 15 20 ft Ibs 20 27 Nm lubricate o ring with oil before installation Item 4d Torque to 20 25 ft Ibs
16. otices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnais sent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Phone Number TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you Minneapolis Local 612 623 6928 Toll Free 1 800 533 9655 or FAX 612 378 8590 All written and visual data contained in this document reflect the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 309098 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 GRACO INC is registered to ISO9001 www graco com PRINTED IN USA January 2000 Revised October 2010 16 309098
17. part of the eguipment determined by Graco to be defective This warranty applies only when the eguipment is installed operated and maintained in accor dance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or sub stitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in 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
18. provided in the 3 8 hydraulic supply line X 3 Connect the 3 8 hydraulic supply line X to the Swivel Y 4 Connect the 3 4 hydraulic tank line T to the Swivel Z 5 Connect the 24 VDC timer controlled signal to the 3 way solenoid valve F 6 Connect supply line G to the lubricant swivel C 7 Ground system see Grounding below Mount reservoir to grounded chassis member Grounding for non mobile installation Loosen grounding lug locknut Fig 1 item A and washer B Insert one end of a 12 ga 1 5 mm2 minimum ground wire C into slot in lug D and tighten locknut securely Connect other end of wire to true earth ground To order a ground wire and clamp order part number 222011 Fig 1 0720 Vent Valve Kit for Custom Tank Part Number 243170 Installation See Figure 3 1 Weld the bracket see Fig 5 in place per recom mended configuration for mounting the vent valve Paint the bracket if desired 2 Connect the hydraulic control line Fig 3 item A to the control module vent valve hydraulic control line Fig 4 item J 3 Connect the high pressure lubricant line Fig 3 item C feeding the injector system to the lubricant output E 4 Connect the vent line F to the lubricant reservoir Control Module Kit for Custom Tank Part Number 243501 Installation See Figure 4 1 Mount the control module on a flat sturdy surface per the recommended configuration see F
19. y Do not exceed the maximum working pressure of the lowest rated component in your system Use fluids and solvents that are compatible with the equipment wetted parts Refer to the Technical Data section of all equipment manuals Read the fluid and solvent manufacturer s warnings Handle hoses carefully Do not pull on hoses to move equipment Route hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 82 C 180 F or below 40 C 40 F Do not lift pressurized equipment Comply with all applicable local state and national fire electrical and safety regulations Be sure breather is not plugged before filling reservoir Be sure unit is securely mounted before operation FIRE AND EXPLOSION HAZARD Improper grounding poor ventilation open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury Ground the equipment and the object being dispensed to See Grounding on page 5 If there is any static sparking or you feel an electric shock while using this equipment stop dispensing immediately Do not use the equipment until you identify and correct the problem Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being dispensed Keep the dispensing area free of debris including solvent rags and gasoline Do not smoke in the dispensing 2 309098 A WARNI
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