Graco Dyna-Star 3A6941J Bedienungsanleitung

3A6941J

Instructions

Compact Dyna-Star®

Electric Pump

Provides lubricant flow and pressure to operate both single line and series progressive

automatic lubrication systems. For automatic lubrication systems only. For professional

use only.

Not approved for use in explosive atmospheres or hazardous (classified) locations.

3500 psi (24.1MPa, 241 bar) Maximum Working

Pressure

See page 3 for model information.

Related Manuals

3A6932 Compact Dyna-Star Auto-Fill Shut Off Kit

3A6998 Compact Dyna-Star 35 lb (5 Gallon) Kit

3A7035 Compact Dyna-Star Pump Cable

333393 Fill Valve

Important Safety

Instructions

Read all warnings and instructions

in this manual and in your injector

manual before using the

equipment. Save these

instructions.

Table of Contents

2 3A6941J

Table of Contents

Pump Model Selection Matrix . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 6

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Single Line Parallel System ............................ 7

Series Progressive System.............................7

Inlet and Outlet Components. . . . . . . . . . . . . . . . 7

Vent Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . 8

Motor Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Motor Electrical Connection . . . . . . . . . . . . . . . . 8

Typical Installation: Single Line Parallel System . 9

Typical Installation: Series Progressive System. 10

Typical Wiring: Single Line Parallel Systems . . . 11

Component Identification . . . . . . . . . . . . . . . . . 12

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fill the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fill Pumps with an Auto-Fill Shut Off (AFSO). . . 15

Refill the Tank: Pumps with an Auto-fill

Shut Off (AFSO) ..................................... 16

Fill Pumps Without an Auto-fill Shut Off

(AFSO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Refill the Tank: Pumps without an Auto-fill

Shut Off..................................................18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Priming the System . . . . . . . . . . . . . . . . . . . . . . 20

Pump Operation Overview. . . . . . . . . . . . . . . . . 20

Single Line Parallel System .......................... 20

Series Progressive System...........................20

Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Level Monitoring . . . . . . . . . . . . . . . . . . . . . . . . 21

Low Level Switch..........................................21

Level Transducer .......................................... 22

Pressure Switch............................................ 23

Pressure Transducer..................................... 23

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Disassemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Related Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Dimensions: Pump with Tank . . . . . . . . . . . . . . . . . . 48

Dimensions: Stand Alone Pump . . . . . . . . . . . . . . . . 49

Dimensions: Stand Alone Pump . . . . . . . . . . . . . . . . 50

Mounting Dimensions: Stand Alone Pump. . . . . . . . 51

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . 52

California Proposition 65 . . . . . . . . . . . . . . . . . . 53

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . 54

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Pump Model Selection Matrix

3A6941J 3

Pump Model Selection Matrix

Pump models are made up of a six-digit part number. The first two digits are fixed alpha characters, while the

remaining four are chosen from the matrix below. Select an item from each column to fill in the model number for

ordering.

Note: Some pump configurations are not available. Contact Graco customer service or your local Graco distributor

for assistance.

Pump Description Metering System Feedback Tank Tank Accessories

112L / 35 lb. Bucket

Length, 24 VDC

0Single Line Progressive,

no vent valve, no pressure

reporting

0No Tank,

Bare Pump

0No Tank,

Bare Pump

220L Tank Length,

24 VDC

1Vent Valve, No Pressure

Reporting

112L Steel Tank

with Follower

Plate

1Low Level Switch

360 lb. Tank Length,

24 VDC

2Vent Valve, Pressure

Switch

220L Steel Tank

with Follower

Plate

2Level Transducer

3Vent Valve, Pressure

Transducer

335 lb. Plastic

Bucket Kit

3Auto-Fill Shut Off and

Low Level Switch

412 L Steel Tank

with no Follower

Plate

4Auto-Fill Shut Off, Level

Transducer

520 L Steel Tank

with no Follower

Plate

660 lb. Steel

Tank with

Follower Plate

760 lb. Steel

Tank with no

Follower Plate

C D 123 4

123 4

Warnings

4 3A6941J

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-spe-

cific hazard symbols and warnings not covered in this section may appear throughout the body of this manual

where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be

aware that flammable fumes can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources, such as cigarettes and portable electric lamps.

• Ground all equipment in the work area.

• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Use only grounded hoses.

•Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment

until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,

or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings

3A6941J 5

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 in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See in all equipment man-

uals. Read fluid and solvent manufacturer’s warnings. For complete information about your mate-

rial, request Safety Data Sheet (SDS) from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine man-

ufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-

ate safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

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.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equip-

ment, follow the Pressure Relief Procedure and disconnect all power sources.

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. Protective equipment includes but is not

limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufac-

turer.

WARNING

Installation

6 3A6941J

Installation

Grounding

To ground the pump: remove the ground screw (Z)

located on the back of the gear box and insert it

through the eye of the ring terminal (W) at end of

ground wire (Y). Fasten the ground screw (Z) back onto

the pump and tighten securely. Connect the other end

of the ground wire (Y) to a true earth ground (FIG. 1). To

order a ground and wire clamp, order Part 222011.

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

To relieve pressure in the system, use two wrenches

working in opposite directions on the pump outlet

fitting to slowly loosen the fitting only until no more

lubricant or air is leaking from the fitting (FIG. 2).

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes

to ignite or explode. Grounding provides an escape

wire for the electric current.

FIG. 1

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. 2

Installation

3A6941J 7

Fuses

Mounting

Note: Upper case letters used in the following

instructions refer to Typical Installation: Single Line

Parallel System (FIG. 5), Typical Installation: Series

Progressive System (FIG. 6), Typical Wiring: Single

Line Parallel Systems (FIG. 7), and Component

Identification (FIG. 8) diagrams starting on page 9.

Securely mount and ground the unit before operation.

1. Mount the tank (K) on a sturdy, flat surface with

user-provided bolts. Install so that the fill port (F)

and the lubricant outlet connection (P or AC) are

easily accessible after installation.

2. Connect the controller (F) (if used).

3. Connect a high pressure lubricant supply line (D) to

the lubricant outlet connection (P or AC).

4. Connect all electrical connections. See Typical

Wiring: Single Line Parallel Systems diagram,

page 11.

5. Ground the system. See Grounding instructions,

page 6.

Pump

The pump provides lubricant flow and pressure to oper-

ate an automatic lubrication system.

Single Line Parallel System

The pump requires an electrical power supply and a

timed signal from a lubrication controller (F). The pump

provides lubricant flow and pressure to operate the

injectors (E), and vents the injector system to reset the

injectors.

Series Progressive System

The pump requires an electrical power supply and a

timed signal from a lubrication controller (F). The pump

provides lubrication flow and pressure to operate

metering devices (AD).

Inlet and Outlet Components

NOTICE

Fuses (user supplied) are required on all models. To

avoid equipment damage:

• Never operate the pump without a fuse installed.

• A fuse of the correct voltage and amperage must

be installed in line with the power entry to the sys-

tem. Graco recommends using a 10A time delay

fuse.

LIFTING HAZARD

This equipment is heavy. Lifting or moving heavy

equipment incorrectly can cause serious injury such

as muscle strain or back injuries. To avoid injury:

• Do not lift or move this equipment without assis-

tance.

• Always use a lifting device secured to the pump

when moving or installing this equipment. See

Technical Specifications, page 52 for pump

weight.

The breather (J) vents the tank to the atmosphere. If it

is plugged the tank will over-pressurize and rupture.

Be sure the breather is not plugged before filling the

pump.

COMPONENT RUPTURE HAZARD

The maximum working pressure of the inlet and out-

let components in the system vary. Over-pressurizing

an inlet or outlet can cause components to rupture,

potentially resulting in serious injury such as skin

injection or injury from splashing fluid. To reduce the

risk of component rupture:

• Be sure to know the maximum working pressure

of each inlet and outlet component in the system.

•Never exceed the maximum working pressure of

the inlet and outlet components.

Installation

8 3A6941J

Vent Valve

The vent valve (L) reduces system pressure in Series

Single Line system and resets the injectors.

Pressure Relief Valve

The pump design includes a self-contained pressure

relief valve (N). When needed, the valve relieves

pressure back into the pump tank (K).

Motor Details

The pump (B) is driven by a 24 V DC brushless motor (1)

with a built-in controller. The motor LED flashes

multiple times during start up and stays on during

operation. Refer to Troubleshooting, page 40 for more

information.

Motor Electrical Connection

FIG. 3

FIG. 4

Installation

3A6941J 9

Typical Installation: Single Line Parallel System

Key:

A Lubricant output connection*

B Pump

C Ignition switch*

D High-pressure lubricant supply lines*

E Injector banks*

F Lubrication controller*

G Fill port

H Overflow port

K Tank

L Vent Valve

NN Bearing*

*User provided

FIG. 5

Installation

10 3A6941J

Typical Installation: Series Progressive System

Key:

A Lubricant output connection*

B Pump

C Ignition switch*

D High-pressure lubricant supply lines*

F Lubrication controller*

G Fill port

H Overflow port

K Tank

NN Bearing*

AD Metering device*

*User provided

FIG. 6

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