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Instructions
Dyna-Star
HF Pump
Provides lubricant flow and pressure to operate a single line automatic lubrication
system. For automatic lubrication systems only. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Models: Page 2
®
HP and
332514J
EN
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Table of Contents
Related Manuals for Graco Dyna-Star 77X000
Summary of Contents for Graco Dyna-Star 77X000
- Page 1 Instructions ® Dyna-Star HP and HF Pump 332514J Provides lubricant flow and pressure to operate a single line automatic lubrication system. For automatic lubrication systems only. For professional use only. Not approved for use in explosive atmospheres or hazardous locations. Important Safety Instructions Read all warnings and instructions in this manual.
- Page 2 Models Models Compatible Reservoirs Maximum Working Pressure Pump Tube in Vent 35/60 90/120 3500 psi 5000 psi Models Tube Pump Pump Valve Pound Pound Pound 24.1 MPa, 241 bar 34.47 MPa, 344 bar 77X000 77X001 77X002 77X003 77X011 77X012 77X013 77X014 77X015 77X016...
- Page 3 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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
- Page 4 Warnings WARNING WARNING WARNING WARNING PRESSURIZED EQUIPMENT HAZARD Over-pressurization can result in equipment rupture and serious injury. • A pressure relief valve is required at each pump outlet. • Follow Pressure Relief Procedure in this manual before servicing. PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture.
- Page 5 Warnings WARNING WARNING WARNING WARNING BURN HAZARD Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns: • Do not touch hot fluid or equipment. PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns.
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Page 6: Typical Installation: Injector System
Typical Installation: Injector System Typical Installation: Injector System The installation shown in below is only a guide for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs. Controller Capabilities Low Reservoir... -
Page 7: Typical Installation: Series Progressive System
Typical Installation: Series Progressive System Typical Installation: Series Progressive System The installation shown below is only a guide for selecting and installing system components. Contact your Graco dis- tributor for assistance in planning a system to suit your needs. Controller... -
Page 8: Installation
Drawings provided on pages 6 and 7. NOTE: • Tank / reservoir covers and reservoirs are available from Graco. Contact your Graco Distributor or Graco Customer Service for assistance ordering these parts. See Parts, page 38 for a complete list of accessories. - Page 9 Installation NOTE: When the pump is correctly installed on the Graco tank, the breather (J) will be below the control 4. Verify gasket (c) is in place on top the reservoir box (115) as shown in F . 9. cover, laying flat and that the holes (e) in the gasket align with the holes in the cover (F .
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Page 10: System Configuration And Wiring
8. Connect the timer/controller (F) (user supplied, if NOTE: Cable wiring harness kits are available from used). Graco. See Parts page 38 for a complete list of available kits. 9. Connect High Pressure Lubricant Supply Line (D) to the Lubricant Output Connection (0) (F . -
Page 11: Installation Instructions
Wiring Installation Instructions 4. Route wires into box. Replace gasket (119) cover (120) and screws (116), being careful not to pinch Reference numbers used in the following instructions any wires. Tighten bolts securely. Torque bolts to refer to Parts, page 36. 17-19 ft.-lbs (23-26 N.m). - Page 12 Wiring 24 VDC With Signal Input Motor Control Board 35 A 18 - 32VDC Sig In Pump Output 5 - 32VDC Lubrication Controller Sig In Pump Output Electric Vent * Valve . 13: Pump control switch shown in signal mode *A Vent Valve is only used in an injector-based system.
- Page 13 Wiring DC Models - Motor Control Board CURRENT SPEED . 15 Fault Table: Red LED (E) - (Negative) Power Input Fault Blinks + (Positive) Power Input Over Current Turn On Signal Locked Rotor Turn On Signal + Red (Fault) LED - Blinks type of fault (See Fault Table) Low or High Voltage Green (Power) LED - High Motor temp...
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Page 14: Current Control And Flow Motor Control Settings
Wiring Current Control and Flow Motor Control Settings Current and Flow control are adjusted on the Motor Control Board using the Current Control Potentiometer Knob (G) and the Flow Control Potentiometer Knob (H) (page 13). Turn knob to clockwise to increase setting value. Turn knob counter-clockwise to decrease setting value. -
Page 15: Operation
Operation Operation Upper case letters used in the following instructions refer to Typical Installation provided on page 6 or 7. COMPONENT RUPTURE HAZARD The maximum working pressure of each component in the system may not be the same. Over pressuriz- ing any component can result in rupture, fire, explo- sion, property damage and serious injury. -
Page 16: Troubleshooting
Troubleshooting Troubleshooting Problem Cause Solution Wiring not done correctly, polarity is Check wire connections. Verify they wrong or loose wire(s) are all tight. Correct polarity. Fuse not in place or fuse is faulty Check fuse rating. If incorrect fuse is Pump not powering ON, green LED used, install fuse of the correct is not ON... - Page 17 Troubleshooting Problem Cause Solution Red fault LED (E) on control board, blinking Over current fault - 1 blink System pressure too high Reduce system pressure by installing larger diameter lubrication tubes Current Control Potentiometer Knob Increase the current limit by turning (G) on motor control board is set too the Current Control Potentiometer Knob (G), clockwise.
- Page 18 Troubleshooting Problem Cause Solution System pressure too high Reduce system pressure by installing larger diameter lubrication tubes. Current Control Potentiometer Knob Increase the current limit by turning (G) on control board is set too low the Current Control Potentiometer Knob (G), clockwise. Separate motor from pump and run Control board temperature is motor.
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Page 19: Seal Replacement
Repair Repair Seal Replacement 5. Loosen bolts (128) and remove cover (126) from Dyna-Star pump (F . 17). Kits 24T860 - HP Models or 24T861 - HF Models • Reference numbers used in the following instruc- tions refer to Parts pages beginning on page 35. •... - Page 20 Repair 7. For Tube-In-Tube models only: Remove bolts (4) e. Use a screw driver to turn motor shaft clockwise holding tube (3) to pump adapter (2). Remove tube until shovel piston (216) is seated in the lowest and gasket (5) and set these parts aside to use for position inside the shovel cylinder (208).
- Page 21 Repair 10. Pull pump adapter (2) down to access retaining 12. Separate displacement rod (212) from connecting spring (8) (F . 23). rod (102) and separate these sections. Put section (102) in a safe place. You will need it for reassem- bly.
- Page 22 Repair wrenches, working in opposite directions to loosen 18. Separate pump cylinder (204) from spacer cylinder shovel cylinder. When cylinder (208) is loose (205) using two strap wrenches, working in opposite enough, use your hands to unscrew and remove it directions to loosen spacer cylinder.
- Page 23 Repair 21. Use a punch and hammer to tap out pins (217) hold- ing the rod sections together (F . 31). Use your hands to unscrew shovel rod (215) and spacer rod (212) from piston (213). . 32 27. Use the displacement rod (212) to push the packing u-cup (202) out of the pump adapter (2) in the direc- tion shown in F .
- Page 24 Repair Reassembly NOTICE NOTE: Sliding displacement rod (212) into the pump adapter from the other side of the pump adapter (2) could • Before reassembly carefully clean and inspect all damage the throat seal (201), resulting in a poor seal parts and pump surfaces for scratches and damage.
- Page 25 Repair 7. Install pin (217) through the aligned holes [(213a 10. Apply a thin layer of grease around gasket (206). . 36) and 212a (F . 37)]. Support rods (212 and Install gasket over end of spacer cylinder (205). 213) as needed to ensure the rods do not bend. Use Slide cylinder over rod assembly as shown in F a pick and hammer to seat the pin inside the rods.
- Page 26 Repair 15. Apply a thin layer of grease to o-ring (209) and HF Pump: install around the seal retainer (211) (F . 41). a. Thread shovel piston (216) to the end of priming rod (215). Hand tighten. 16. Thread seal retainer (211) to pump cylinder (204) with the seal end installed inside the pump cylinder b.
- Page 27 24T865 for 400 pound pumps are available from 23. Align the two gasket seals (9) in pump adapter (2) Graco. See Parts, page 38 for information about with two holes (103b) in gear box pump bracket ordering these kits or contact your Graco Distributor (103).
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Page 28: Motor Replacement: Kit 24T862
Repair Motor Replacement: Kit 24T862 NOTE: When the pump is correctly installed, the breather (J) will be below the control box (115) as shown in F . 49. • Reference numbers used in the following instruc- tions refer to Parts pages beginning on page 35. •... - Page 29 Repair 5. Remove screws (116) from motor control box cover 7. Disconnect sensor cable (117a) from motor control (120) and remove cover and gasket (119) (F . 53). board (F . 54). 8. Use a wrench to loosen strain relief (a) and remove wiring harness from housing (F .
- Page 30 Repair Reassembly 5. Match green, yellow and blue wires to terminals of same color (written on the motor control board). NOTE: Secure wires to terminals using washers and nuts (134 and 135) (F . 59). Torque to 8-10 in. lbs (0.9 - •...
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Page 31: Motor Control Board Replacement: Kit 24T867
Repair Motor Control Board wires. Tighten screws securely. Torque to 17-19 ft lbs (23 -25 N.m). Replacement: Kit 24T867 • Reference numbers used in the following instruc- tions refer to Parts pages beginning on page 35. • Upper case letters used in the following instructions refer to Typical Installation provided on page 6 or 7. - Page 32 Repair 5. Remove screws (116) from motor control box cover 7. Disconnect sensor cable (117a) from motor control (120) and remove cover and gasket (119) (F . 63). board (F . 65). 8. Disconnect source to power input (A and B) and pump control connections (C and D) (See F .
- Page 33 Repair Reassembly 3. Match green, yellow and blue wires of motor to ter- minals of same color (written on the control board). NOTE: Secure wires to terminals using washers (135) and nuts (134) (F . 59). Torque to 8 - 10 in. lbs (0.9 - •...
- Page 34 Repair 5. Replace motor control board gasket (119) and cover (120) with screws (116) (F . 70) being careful not to pinch any wires. Tighten screws securely. Torque to 17 - 19 ft lbs (23 - 25 N.m). . 70 6.
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Page 35: Parts List
Parts List Parts List Main Assembly All Models Replacement Danger and Warning labels, tags, and cards Ref. are available at no cost. Part No. Description BOX, gear, model (page 36) Included in Tube-In-Tube Kit 24T863 (60 pound), 24T897 KIT, adapter, pump, HP models 24T864 (90 pound), 24T865 (400 pound). -
Page 36: Gear Box
Parts List Gear Box PACKING, o-ring 162841 Ref. Part No. Description MOTOR, 24VDC WASHER, lock HOUSING, gear box ROD, connecting SCREW, cap, hex head BRACKET, gear box to pump COVER, shroud SCREW, M8 BOLT, M6 ... - Page 37 Parts List HP Model Pump Lower: 16T857, HF Model Pump Lower: 16T706, 16N700, 16T757 16T821, 16T822 Ref. Ref. Part No. Description Part No. Description 24T897 KIT, adapter, pump 24T898 KIT, adapter, pump 15C530 NUT, retainer 16F947 NUT, retainer PACKING, u-cup, throat, hp †...
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Page 38: Pump Lower Parts
Parts List Pump Lower Parts Cable Harness Kits Part No. Description 77X527 CABLE, power, series progressive system only. Use with 77X528. 77X529 CABLE, power, injector system only. Use with77X528. 77X528 CABLE, power, extension, 15 ft (4.6 m). Used with 77X527 and 77X529 24N402 CABLE, 6 ft, vent valve, 2 pin for vent valve control 77X533 KIT, cable, gland... -
Page 39: Technical Data
Technical Data Technical Data Dyna-Star HP or HF Lubrication Pump Metric Maximum Working Pressure HF Models 3500 psi 24.1 MPa, 241 bar HP Models 5000 psi 34.47 MPa, 344 bar Electrical Requirements All Models 24VDC Wire Terminal AWG Size for Control Board 24 to 10 AWG Input Voltage Range 24 VDC... - Page 40 Dimensions Dimensions 60 Pound Models 90 lb Models 400 lb Models US (inch) Metric (mm) US (inch) Metric (mm) US (inch) Metric (mm) 36.5 44.3 1125 16.8 16.8 16.8 10.6 10.6 10.6 11.0 11.0 11.1 11.1 11.1 332514J...
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Page 41: Performance Charts
Dimensions Performance Charts To find the Current (Amp) at a specified Flow Rate To find the Flow Rate (in /min.) at a specified cur- /min.): rent (Amp): 1. Locate the specified Flow Rate on the vertical axis. 1. Locate the specified Current on the horizontal axis. 2. - Page 42 Dimensions Graph 2: HF Model at 14°F (-10°C) (573.55) (491.61) (409.98) (327.74) (245.81) (163.87) (81.94) 332514J...
- Page 43 Dimensions Graph 3: HP Model at Ambient Temperature (327.74) (294.97) (262.19) (229.42) (196.64) (163.87) (131.10) (98.32) (65.55) (32.77) 332514J...
- Page 44 Dimensions Graph 4: HP Model at -40°F (-40°C) (229.42) (196.64) (163.87) (131.10) (98.32) (65.55) (32.77) 332514J...
- Page 45 Notes Notes 332514J...
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Page 46: 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.