Graco 96G017 Instruction Manual
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Graco 96G017 Instruction Manual

G3 max automatic lubrication pump
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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) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Conforms to ANSI/UL 73
Certified to CAN/CSA
Std. 22.2 No 68-09
3132066
332305B
EN
TI14705

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  • Page 1 Instructions G3 Max Automatic Lubrication Pump 332305B 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) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this...
  • Page 2 Graco Standard Warranty ....76 Graco Information ..... . . 76...

  • Page 3: Part / Model Numbers

    The Part Number is a six-digit unique number that is only used to order the G3 Pump. Directly related to this six digit Part Number is the configured Graco Model Number. This configured number identifies the distinct features of a spe- cific G3 Pump.

  • Page 4: Liter Models

    Part / Model Numbers 8 Liter Models 12 Liter Models Part Part Model Numbers Model Numbers Numbers Numbers 96G105 G3-G-24MX-120L00-1DMVA2R3 96G089 G3-G-24MX-8L0L00-10CV00R0 96G120 G3-G-ACMX-120L00-1DMVA2R3 96G093 G3-G-ACMX-8L0L00-1D0V0000 96G164 G3-G-24MX-120L05-10CV00000 96G097 G3-G-12MX-8L0L00-1DMVA2R3 96G165 G3-G-24MX-120L05-U0CV0100 96G100 G3-G-12MX-8L0L00-UDMVA1R2 96G104 G3-G-24MX-8L0L00-1DMVA2R3 16 Liter Models 96G109 G3-A-24MX-8L0L00-1DMVA2R3 96G112 G3-G-24MX-8L0L00-UDMVA1R2...

  • Page 5: Understanding The Model Number

    Use the Code Sample provided below to identify each component’s location in the Model Number. The options for each component that make up the code are provided on the lists below. NOTE: Some pump configurations are not available. Contact Graco Customer Service or your local Graco distributor for assistance.

  • Page 6: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. When these symbols appear in the body of this manual, refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.
  • Page 7 Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. •...

  • Page 8: Component Identification

    Pressure Relief Valve (Not included / required for each outlet Power Cord (DIN shown) - Available from Graco. See Parts, page 71.) Follower Plate (grease models only / not available on all Zerk Inlet Fill Fitting (1 included / grease models only)

  • Page 9: Typical Installation

    Typical Installation Divider Installations Injector Installations Connected to fuse / power Vent valve (Not included / available from Graco. See Pressure relief valve (Not included/required for each Parts, beginning on page 67.) outlet - user supplied. See Parts, page 71)

  • Page 10: Choosing An Installation Location

    G3. No other installation configurations should G3 to the mounting surface. be used. • Some installations may require an additional • Use designated mounting holes and provided reservoir support bracket. Consult your Graco configurations only. distributor for assistance with this installation. 332305B...

  • Page 11: System Configuration And Wiring

    • it must be connected to a grounded, permanent wir- Fuse Kits are available from Graco. The following Table ing system. identifies the correct fuse to use for your input voltage and the corresponding Graco Kit number.
  • Page 12 An internal representative wiring diagram is included where it is deemed useful. Wire colors provided on these pages only refer to the power cable provided by Graco with this product. Standard Remote...
  • Page 13 Installation Wiring and Installation Diagrams The following Table identifies the wiring and installation diagrams provided in this manual. Diagram Symbol Page # Power DIN AC Power DIN DC Power CPC DC Inputs (M12) Vent Valve Outputs Alarm Outputs Kits: 571030, 571031, Illuminated Manual Run Input 571032, 571033 332305B...
  • Page 14 Installation Power DIN AC - 15 foot: Part No. 16U790 Pin and Related Wire Color (F . 3) Pin Pin Name Color Line Black NEUTRAL White Not Used Not Used GROUND Green Connector on Housing Connector on Cable Example Wiring Diagram 332305B...
  • Page 15 Color -VDC Black +VDC White Not Used Not Used Not Used Green Connector on Housing Connector on Cable Example Wiring Diagram Ignition Switch Fuse 12V-pump - 7.5A - Graco kit #571039 24V pump - 4A - Graco kit #571040 332305B...
  • Page 16 Not Used Not Used Not Used Not Used Not Used Not Used Green Connector on Housing Connector on Cable Example Wiring Diagram Ignition Switch Fuse 12V-pump - 7.5A - Graco kit #571039 24V pump - 4A - Graco kit #571040 332305B...
  • Page 17 571031 for starting a manual run cycle if used in con- +VDC junction with a 5-wire CPC cable, is available from LIGHT White Graco. Contact your local Graco distributor or Graco MANUAL ORANGE Customer Service for additional information about these kits.
  • Page 18 Installation Inputs (M12) See Technical Data, page 72 for rat- ings. Connector on Housing Pin-out 1 SW + 2 Not Used 3 SW - 4 Signal Example Wiring Diagram Dry Contacts Sink (NPN) 2 or 3 wire Source (PNP) 2 or 3 wire 332305B...
  • Page 19 Installation Vent Valve Outputs See Technical Data, page 72 for ratings. Connector on Housing Pin-out 1 Not Used 2 Relief+ 3 Relief - Example Wiring Diagram 332305B...
  • Page 20 Installation Alarm Outputs DC example shown. See Technical Data, page 72 for ratings. Connector on Housing Pin-out 1 N.O. 2 N.C. 3 COM 4 Not Used Example Wiring Diagram Alarm +9-30V 1 Amp Max Switch closes on alarm (shown in non-alarm position) 332305B...
  • Page 21 Installation Part No. 124333: Cable Pin Out (M12) Part No. 124300: Field Wireable Pin Out Wire Colors (M12) Item No. Color Wire Colors Brown Item No. Color White Brown Blue White Black Blue Black &DEOH 3LQ 2XW )LHOG :LUHDEOH 3LQ 2XW )HPDOH (QG 9LHZ )HPDOH (QG 9LHZ 0DOH (QG 9LHZ...
  • Page 22 Installation Part No. 124594: 4 Pin Eurofast Field Part No. 124595: 5 Pin Eurofast Field Wireable Connector Wireable Connector . 13 . 12 332305B...

  • Page 23: Setup

    See Technical Data, page 66. • Install a pressure relief valve close to every pump outlet; before any auxiliary fitting. . 14 NOTE: A pressure relief valve can be purchased from Graco. See Parts, page 71. 332305B...

  • Page 24: Setting Pump Outlet Volume

    • Before making any adjustments to pump volume, Relieve Pressure following procedure on page 23. • Only use Graco supplied spacers to control output volume. • It may be necessary to repeat this outlet volume setup procedure after the pump is operating to re-adjust the volume of dispensed fluids.
  • Page 25 Setup Models without a follower plate: To start the pump press the manual run button. 1. Connect fill hose to inlet fitting (F . 16). 3. Fill reservoir with grease until seal of follower plate breaches the vent hole (F .

  • Page 26: Filling Oil Unit

    Setup 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. • The reservoir can be filled using a hand operated pump, pneumatic pump or electric transfer pump. •...

  • Page 27: Quick Setup Guide

    Quick Setup Guide Quick Setup Guide 0D[ 0RGHO 6\VWHP  ,QMHFWRU 6\VWHP ZLWK 6LQJOH 6HQVRU ,QSXW 6HOHFW (QWHU (QWHU 6HWXS 21%DFNXS 7LPH 0066 (QWHU 6\VWHP 3UHOXEH 5XQV 2SWLRQ 7LPH $FFRUGLQJ ++00 WR 6HWWLQJV (QWHU 3UHOXEH 'HOD\ 0066 0D[ 0RGHO 6\VWHP  'LYLGHU 9DOYH 6\VWHP ZLWK 6LQJOH 6HQVRU ,QSXW 6HOHFW 3UR[ VHQVRU (QWHU...

  • Page 28: Max Model Setup

    Max Model Setup Max Model Setup Control Panel Overview (F . 22) NOTE: Programming instructions begin on page 29. OFF TIME/BACKUP TIME • DISPLAY LED lights when OFF Time/Backup Time is used to con- • A blinking LED under HH, MM, SS trol Pump OFF function.

  • Page 29: Programming The Max Model

    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 programming settings and therefore, an option for adding PIN Code authorization is available.
  • Page 30 Max Model Setup Setting the Real Time Clock the list of months until the current month is dis- played in the field. ™ Equipped Models Only 2. Press the ENTER button to set the NOTE: Set the real time clock prior to plugging the USB month.
  • Page 31 Max Model Setup • The first programmable number of the HH (hour) • The LED next to C/P1 lights, indicat- filed blinks, indicating the device is ready to program ing which sensor of the pump control the first digit of the hour. you are programming using either a specific number of cycles or by mon- •...
  • Page 32 Max Model Setup 4. The cycle field is a 2 digit number. 3. If your G3 comes equipped with more than one sen- When the correct first numeral of the sor input, you will automatically be prompted to number displays, press the ENTER but- begin selecting pump control type for the next sen- ton to save the number.
  • Page 33 Max Model Setup To determine the Backup Time, Graco recommends the 6. After pressing the ENTER button to set user verify the length of time it takes to complete a typi- the last SS field, all the programmed ON cal cycle and double that value (to a maximum of 30 Time information is saved.

  • Page 34: Pump Off / Rest Setup

    Max Model Setup 2. Press the ENTER button to lock in the indicating you are now in the Machine Count setup selection. The next MM number field to mode. the right flashes indicating it is ready for 2. Press the UP or DOWN programming.
  • Page 35 • An LED flashes under If this time does not meet the application needs, either HH when pro- contact Graco Customer Support. gramming hours OR MM when program- Programming Backup Time ming minutes. NOTE: When programming a Backup Time of less than 10 hours you must program a leading zero in the first •...
  • Page 36 Max Model Setup 1. To set the OFF Time use the 2. OFF displays. If you UP or DOWN ARROW button want the prelube to scroll through numerals 0 cycle to begin imme- to 9 until the desired number diately, leave this set appears in the first HH (hour) to OFF.

  • Page 37: Dms ™ Models Only

    3. “data” is displayed while the system The pump program settings file is named: is downloading files. GRACO/G3Config/g3config.bin. This file cannot be 4. When download is finished, “done” is modified. Modification of the file or file name may cause displayed.
  • Page 38 Max Model Setup 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 29).

  • Page 39: Operation / Data Log

    Logs contain the following information: DMS ID Number: 0025 (see page 38) • Log Name Software Part Number: 16F821 • DMS ID Number Software Version: 1019 • Current Software Graco Part Number 09/29/2010 14:1400 • Current Software Version Date Time Description •...

  • Page 40: Error Log

    The log file is stored as: panel and holding it for 3 seconds. G3 Power On The pump powered on. GRACO/G3_{DMS_id}/{download date - YYYYm- G3 Power Off The pump powered off. mDD}/ERRORLOG.CSV Program Variable The setup mode was entered.
  • Page 41 Warning is above the designated oper- Software Fault An internal software error ating. Check the unit and sys- occurred. Contact Graco Cus- tem to determine that it is tomer Service. functioning correctly. Operating Low Level Warning The unit entered a low level...

  • Page 42: Functional Summary

    This is very similar to an odometer in your car. Technical User Summary, page 49). The log file is stored as: This is very similar to the resettable trip odometer in your car. GRACO/G3_{DMS_id}/{download date - YYYYm- mDD}/FUNCSUM.CSV Example: GRACO/G3_00025/20100911/FUNC- SUM.CSV Sample Functional Summary...
  • Page 43 Operation / Data Log Common Functional Summary Data entries are listed below. Number of Cycles The number of lubrication cycles the unit has started. Total Run Hours Total amount of hours the pump has been in the ON mode of the ON/OFF cycle.

  • Page 44: Technical Summary

    The log file is stored as: Low Internal Tempera- The lowest internal temperature ture seen by the unit. GRACO/G3_{DMS_id}/{download date - YYYYm- mDD}/TECHSUM.CSV Sample Technical Summary G3 Technical Summary DMS ID Number: 00025 (see page 38) Software Part Number:16F821...

  • Page 45: Advanced Programming

    Advanced Programming Advanced Programming There are 7 Advanced Programming options. The following Table Identifies each option and when it is used. Advanced Model Setting Format/ Description Why Use This? Option Lockout Secures setup modes with Prevents unauthorized users to adjusting Code settings.
  • Page 46 Advanced Programming Entering a PIN Code for the First Time 1. The cursor is automatically positioned to enter the first character of the PIN Code. A1 - Setting Up PIN Code Use the UP and DOWN A PIN Code can be programmed into the G3 to protect ARROW buttons to move up the settings from inadvertently being changed by unau- and down through the numbers 0-9 until the first...
  • Page 47 Advanced Programming A2 - Low Level Alarm Time 3. Use the UP or DOWN ARROW button to scroll Pump ON mode only. through numerals 0 to 9 until Programs the amount of time in MM: SS (minutes and the desired number appears seconds) the pump can run between a Low Level Warn- in the second MM number ing and a Low Level Fault to help protect unit from run-...
  • Page 48 The default setting is 0. For assistance • Time is set as minutes and seconds (MM:SS) only. determining a reasonable number of Alarm Retries to program for your application, contact Graco Customer • The small flashing Service or your local Graco distributor.
  • Page 49 Advanced Programming 3. When the correct number displays, 3. Press the ENTER button to exit press the ENTER button to set the num- Advanced Programming. ber. A6 - Clearing the Functional and Technical 4. Repeat 2 - 3 to set the remaining fields. ™...
  • Page 50 Advanced Programming A-7- Constant Alarm Output on Fault This function changes the behavior of the alarm output in a fault from either toggling once every second (default) or steady on. Fault and Warning LEDs Illuminate MM : SS HH : MM 1 2 3 .

  • Page 51: Run Mode

    Run Mode Run Mode • When the OFF Time count reaches zero, the G3 Automatic Lubrication Pump turns the pump on and it runs for the programmed ON Time cycle (F . 29). Time Control (Notice the ON Time LED is now illuminated on the display.) After setup is complete, the G3 automatically begins to •...
  • Page 52 Run Mode Lubrication Mode (Pump ON) Controls Pressure Control In Max models the Lubrication Mode (Pump ON) can be • A single triggered count in a pressure based controlled by either cycle and/or pressure sensors. system (P1). Typically a pressure switch on the end of a line of injectors.
  • Page 53 Run Mode Backup Time • In both Cycle and Pressure modes a Backup Time (maximum run time) has been set. • The LED(s) next to all programmed sensors (C/P1, C/P2, C/P3) illuminate. • The display shows time remaining until a fault. The example shown in F .
  • Page 54 Run Mode With machine count set, the Rest Cycle (Pump OFF) is Backup Time ended when the machine count reaches zero (0000). In Machine Count mode, if a Backup Time (maximum rest time) has been set: Machine Count • A set number of triggered counts. •...
  • Page 55 Run Mode Additional Controls Prelube The Prelube function has been selected. Prelube delay Venting is set to 00:00: In Max models a Vent Time can be set using the • Power to the unit cycles OFF then ON. Advanced Programming mode (page 47). This is typi- cally done in a Pressure Based System (P1) to allow •...
  • Page 56 Run Mode Manual Run Cycle To run an extra (non-programmed) lubrica- tion cycle, push the Manual Start button. NOTE: Manual Run option is not available while unit is in Vent Mode. 332305B...

  • Page 57: Alarms

    Alarms Alarms Any time a Fault / Warning occurs, a combination of LED’s will illuminate to notify you there is a problem and help identify the kind of Fault / Warning has occurred. • Faults and Warnings will not automatically clear. •...
  • Page 58 Alarms Low Level Level of lubricant in Add lubricant to reservoir. Fault reservoir is low and addi- tional lubricant needs to be After lubri- added. cant is added press Unit stops pumping and and hold the displays amount of accu- RESET button to clear mulated time since the fault.
  • Page 59 Alarms Cycle / In pressure mode indi- Examine system to deter- mine if you have a Pressure cates that unit is over pres- Fault surized or a lubrication plugged or broken line or cycle was not completed in other component failure, the user-defined amount of i.e., divider valve, injector.
  • Page 60 Alarms System An internal fault has Contact Graco Customer Fault occurred. Service. MM : SS HH : MM 1 2 3 Motor Cur- The measured motor cur- Examine system to make rent Warn- rent is above the recom- sure it is operating cor- mended operating rectly.
  • Page 61 Use of the unit outside of 158° F (-25° C to 70°C). the recommended tem- perature range could cause If necessary contact degraded system perfor- Graco Customer Service. MM : SS HH : MM mance and possible dam- age. 1 2 3...

  • Page 62: Troubleshooting

    Maximum duty cycle is 33% (2 min- Adhere to allowable duty cycle. Con- utes OFF for each minute ON) tact Graco Customer Support if other Can’t set desired ON/OFF times duty cycles are required for applica- tion.
  • Page 63 • Retry using a different flash drive. If any of the above do not rectify the error, contact Graco Customer Ser- vice. Pump program setting file not found Verify that the pump program setting folder structure and file are stored USB Error 11 correctly on the flash drive.

  • Page 64: Maintenance

    Maintenance Maintenance Frequency Component Required Maintenance Daily and at refill Zerk Fittings Keep all fittings clean using a clean dry cloth. Dirt and/or debris can dam- age pump and/or lubrication system. Daily G3 Pump Unit and Reservoir Keep pump unit and reservoir clean using a clean dry cloth.

  • Page 65: Parts - 2 Liter Models

    Parts - 2 Liter Models Parts - 2 Liter Models Follower Plate Models Only Low Level Grease Models Only Low Level Oil Models Only Torque to 4 in. lbs (0.45 N.m) Torque to 30 in. lbs (3.4 N.m) Torque to 50 in. lbs (5.6 N.m) 332305B...

  • Page 66: Parts - 4 Liter And Larger Models

    Parts - 4 Liter and Larger Models Parts - 4 Liter and Larger Models Follower Plate Models Only Low Level Grease Models Only 27 1 Low Level Oil Models Only Torque to 4 in. lbs (0.45 N.m) Torque to 30 in. lbs (3.4 N.m) Torque to 50 in.

  • Page 67: Parts

    PUMP, element, included in Kit PADDLE, stirring, 2 Liter models 571041 without follower plate - models SPACER, stroke adjust, included in 16F368 96G017, 96G019, 96G021, Kit 571041 96G023, 96G025, 278145 PLUG, pump, 3/4-16 96G030-96G032, 96G035-96G037, 96G098, 96G110, 96G125, PADDLE, low level, models...
  • Page 68 Parts Part Description Part Description BOARD, circuit, Max, models WIPER, stirring, models without fol- 96G017-96G021, 96G023-96G026, lower plate - models 96G017, 96G030-96G032, 96G035-96G037, 96G019, 96G021, 96G023, 96G088-96G090, 96G092-96G094, 96G025, 96G030-96G032, 96G096, 96G097, 96G035-96G037, 96G088, 96G103-96G109, 96G113, 96G089, 96G092, 96G093, 258697...
  • Page 69 SPRING, compression, 4 liter mod- 96G133, 96G145, 96G146, els 96G090, 96G094, 96G113, 96G166, 96G174-96G176, 96G183 96G116, 96G128, 96G133 BAFFLE, low level, 2 liter models 96G017, 96G019, 96G021, 96G023, 96G025, 96G030 - 45† 24D838 96G032, 96G035-96G037, 96G098, 96G110, 96G125, 96G178 332305B...
  • Page 70 Part Description Part Description WASHER, low level, models CABLE,15 ft (4.5 m), SOOW 126217 96G017-96G021, 96G023-96G026, w/7pos, 3 pin, 90 deg 96G030-96G032, 96G035-96G037, CABLE, 15 ft (4.5 m), SOOW w/7 126218 96G088-96G090, 96G092-96G094, pos, 5 pin, 90 deg 96G096-96G100, 96G103-96G106, CABLE, 20 ft (6.1 m), SOOW, w/7...
  • Page 71 Parts Pressure Relief Valves Fuses Important Information regarding Pressure Relief Part Description Valve 16C807. 571039 FUSE, 12 volt DC  Pressure Relief Valve 16C807 can only be used on the G3 Pump. It is not intended for use with any other 571040 FUSE, 24 volt DC products.

  • Page 72: Technical Data

    Technical Data Technical Data Maximum Working Pressure 5100 psi (35.1 MPa, 351.6 bar) Power 100-240 VAC 88 - 264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz, Single phase, inrush/locked rotor, max 40A (1ms) 12 VDC 9 - 16 VDC; 5 A current, 60 W, inrush/locked rotor 12 A 24 VDC 18 - 32 VDC;...

  • Page 73: Dimensions

    Technical Data Fluid Grease Models Grease NLGI 000 - #2 Oil Models At least 40 cSt oil. Pumps Up to 3 Pump Output 0.12 in. (2 cm ) / minute per outlet - 2 spacers 0.18 in. (3 cm ) / minute per outlet - 1 spacer 0.25 in.

  • Page 74: Mounting Pattern

    Technical Data Mounting Pattern (For correct mounting configuration, choose either Option 1 or Option 2). See P/N 126916 template. Option 1 0.367inch 7.087 inch 9.3 mm 180.0 mm 2x Ø 0.366 inch 1.180 inch 9.3 mm 30.0 mm 3.268 inch 83.0 mm 3.544 inch 90.0 mm...
  • Page 75 Notes Notes 332305B...

  • Page 76: Graco Standard Warranty

    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 part of the equipment determined by Graco to be defective.

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