G1??? Plus

Lubrication Pump

332317C

EN

The equipment must be grounded. Grounding reduces the risk of electric shock by providing an escape wire for the electrical current in the event of malfunction or breakdown.

Component Identification

K

Oil Models

Grease Models

A

E

D

F

B

GL

FIG. 1:

H

J

Grease Models with Follower Plate

C

???Select a location that will adequately support the weight of the G1 Pump and lubricant, as well as all plumbing and electrical connections.

???Refer to the two mounting hole layouts provided in the Mounting Pattern section of this manual, page 33.

NOTE: The two mounting hole layouts provided in the Technical Data section show the only correct installa- tion patterns to use for mounting the G1. No other installation configurations should be used.

???Use designated mounting holes and provided config- urations only.

???Always mount the G1 oil models upright.

???If the G1 grease model is going to be operated in a tilted or inverted position for any period of time, you must use a model that includes a follower plate, oth- erwise the G1 must be mounted upright.

???Use the three fasteners (included) to secure the G1 to the mounting surface.

System Configuration and

Wiring

.

Improper installation of the grounding conductor may result in a risk of electric shock. This product must be installed by a qualified electrician in compliance with all state and local codes and regulations.

If the product is permanently connected:

???it must be installed by a qualified electrician or ser- viceman.

???it must be connected to a grounded, permanent wir- ing system.

If an attachment plug is required in the end use application:

???it must be rated for the product electrical specifica- tions.

???it must be an approved, 3-wire grounding type attachment plug.

???it must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Installation

???when repair or replacement of the power cord or plug is required, do not connect the grounding wire to either flat blade terminal.

Fuses

NOTICE

Fuses (user supplied) are required on all DC models. To avoid equipment damage:

???Never operate G1 Pump DC models without a fuse installed.

???A fuse of the correct voltage must be installed in line with the power entry to the system.

Fuse Kits are available from Graco. The following Table identifies the correct fuse to use for your input voltage and the corresponding Graco Kit number.

Recommendations for Using Pump in Harsh Environments

???Use pump with CPC style power cable.

Connector on Cable

(2)

(7)

(3)

(1)

(4)

(6)(5)

Setup

Setup

Pressure Relief

Follow the Pressure Relief Procedure when- ever you see this symbol.

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 spraying and before cleaning, checking, or servicing the equipment.

Relieve pressure in system using two wrenches work- ing in opposite directions on pump element and pump element fitting to slowly loosen fitting only until fitting is loose and no more lubricant or air is leaking from fit- ting.

NOTE: When loosening pump element fitting, do NOT loosen pump element. Loosening pump element will change the output volume.

FIG. 6

Connecting to Auxiliary Fittings

NOTICE

Do not attach unsupported equipment to auxiliary fittings such as fill ports and pump element. Attach- ing unsupported equipment to these fitting can result in irreparable housing damage.

???Always use two wrenches working in opposite directions when connecting anything to pump element or auxiliary fittings. See FIG. 6 for an example.

???Torque pump element fittings to 50 in. lbs (5.6 N???m).

???When connecting pump element into housing torque to 50 in. lbs (5.6 N???m).

Pressure Relief Valves

A pressure relief valve appropriate for the lubrication system must be installed close to the pump outlet to alleviate unintended pressure rises in the system and protect the G1 pump from damage.

???Only use a pressure relief valve that is rated for no more than the working pressure of the G1 pump it is installed on. See Technical Data, page 26.

???Install a pressure relief valve before any auxiliary fitting.

Loading Grease

To ensure optimal performance from the G1:

???Only use NLGI #000 - #2 greases appropriate for your application, automatic dispensing, and the equipment???s operating temperature. Consult with machine and lube manufacturer for details.

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

???Do not overfill (FIG. 8).

???Do not operate G1 without reservoir attached.

NOTICE

???Always clean fitting (37) with a clean dry cloth prior to filling reservoir. Dirt and/or debris can damage pump and/or lubrication system.

???Care must be used when filling the reservoir using a pneumatic or electric transfer pump to not pressurize and break the reservoir.

Models without a follower plate:

1. Connect fill hose to inlet fitting (37) (FIG. 7).

37

FIG. 7

2.For higher viscosity fluids, press the manual run button to start the pump during fill to rotate the stirring paddle and prevent air pockets from forming in grease.

Setup

3. Fill reservoir with NLGI grease to max fill line.

NOTE: Vent port, located in rear of reservoir, should not be used as an overfill port/indicator.

max fill line

FIG. 8

4. Remove fill hose.

Models with a follower plate:

1.Connect fill hose to inlet fitting (FIG. 7).

2.For higher viscosity fluids, press the manual run button to start the pump during fill to rotate the stirring paddle and prevent air pockets from forming in grease.

3.Fill reservoir with grease until seal of follower plate breaches the vent hole (FIG. 9) and the majority of air is expelled from the reservoir.

vent hole

FIG. 9

NOTE: Vent port, located in rear of reservoir, should not be used as an overfill port/indicator.

4. Remove fill hose.

Setup

Changing Greases

When changing greases, always use compatible fluids or greases.

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.

???Do not overfill (FIG. 10).

???Do not operate G1 without reservoir attached.

???Only use oils with viscosity at least 40 cSt.

a

b

Priming

NOTE: It is not necessary to prime pump every time pump is filled with lubricant.

Pump only requires priming the first time it is used or if it is allowed to run dry.

1. Loosen pump element fitting (FIG. 11).

NOTE: When loosening pump element fitting, do NOT loosen pump element. Loosening pump element will change the output volume

FIG. 11

FIG. 10

1.Remove fill cap (a).

2.Pour oil into reservoir to fill line (b).

3.Replace fill cap. Hand tighten cap, securely.

2.Only run pump until air is no longer dispensed with the lubricant coming out of element fitting (FIG. 12).

FIG. 12

3.Tighten pump element fitting using two wrenches working in opposite directions (FIG. 11).

Plus Model Control Setup

Control Panel Overview (FIG. 13)

NOTE: Programming instructions begin on page 22.

OFF TIME

Plus Model Control Setup

ON TIME

???The blinking LED below ON indicates the ON Time sequence is running.

???Display shows time as MM (minutes).

i.e., 02 is 2 minutes.

??? Times lubrication cycle.

???Counts down from a set time to zero.

???The blinking LED below OFF indicates the OFF Time sequence is running.

???Value is entered in HH.

???Displays in HH.

???Times pump rest between cycles.

???Counts down from a set time to zero.

ON OFF

MM HH

Lubrication Pump

LOW LEVEL FAULT

LED next to icon lights when pump is out of lubricant. Pump run cycle stops.

LOCK ICON

???LED next to icon lights indi- cating PIN is required to enter setup.

???In SETUP MODE LED lights when setting up the PIN.

RIGHT DIRECTION ARROW /

MANUAL RUN / ENTER:

LEFT DIRECTION ARROW /

RESET

???In SETUP MODE, moves cur- sor in display one field to the left.

???In Low Level Fault Mode: press- ing and holding for 3 seconds clears fault and switches cycle to OFF MODE.

UP and DOWN ARROW

???Hold both the UP and DOWN ARROW but- tons down together for 3 seconds to enter

SETUP MODE.

???In SETUP MODE, increases or decreases number values shown in display.

???In SETUP MODE, saves entry, moves cursor in display one field to the right or to the next setup step.

???In RUN MODE starts a man- ual run cycle.

Plus Model Control Setup

Instructions

Powering Units With Controllers

By default, units with controllers are set to operate in a timed mode with 1 minute of ON time and 8 hours of OFF time. The unit should be powered up in OFF mode,

counting down from the 8 hours. If the unit powers up in ON mode and has not been primed, hold the reset but- ton located on the control panel (example shown on the right) for 1 second to move to the OFF mode.

The G1 Plus model uses a timer to regulate how long a pump cycle runs and the length of time the pump rests between cycles.

NOTE:

???A blinking number on the display indicates the G1 is in SETUP MODE.

???In RUN MODE numbers on the display do not blink.

???After 60 seconds of no activity, the device returns to RUN MODE in the OFF Time 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 PIN Code lock out enabled. See Entering a PIN Code to Access Setup Mode for instructions on entering a value.

ON OFF

MM HH

Entering a PIN Code to Access Setup Mode

The G1 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 program settings and therefore, an option for adding PIN Code authorization is available. The instructions for setting a PIN Code are provided in the Advanced Programming section of this manual. See page 24.

To enter the PIN Code:

1.Press both the UP and DOWN ARROW buttons for 3 seconds.

2.The LED next to the LOCK ICON on

the display lights and the 4 zeros appear on the display indicating the

system requires a PIN Code entry to access the G1 in SETUP MODE.

3.The cursor is automatically positioned to enter the first character of the PIN Code. Use the UP and DOWN ARROW buttons to move up

and down through the numbers 0-9 until the first number in the PIN code is displayed in the field.

4.Press the ENTER button to set the num- ber. The cursor automatically moves to the next number field.

5.Repeat steps 3 and 4 for each PIN Code prompt field.

If the PIN Code you entered is correct, the first editable character on the display will flash.

NOTE: A blinking field on the display indicates the G1 is in SETUP MODE. In RUN MODE numbers on the dis- play will not blink.

ON Time

???ON Time is set in Minutes (MM).

Programming ON Time

NOTE: When programming a time of less than 10 min- utes you must program a 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 3 until the desired number appears in the first MM (min- utes) field.

2.Press the ENTER button. The next MM number field to the right flashes indicat- ing it is ready for programming.

3.Use the UP or DOWN ARROW button to scroll through numerals 0 to 9 until the desired number appears in the second MM number field.

4.After pressing the ENTER button to set the last MM field, all the programmed ON Time information is saved.

The G1 automatically switches to the OFF Time

SETUP MODE.

Plus Model Control Setup

OFF Time

???OFF Time is set in Hours (HH).

Programming OFF Time

NOTE: When programming a time of less than 10 hours you must program a leading zero in the first num- ber field and press the ENTER button to save the zero selection.

1.To set the OFF 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 through numerals 0 to 2 until the desired number appears in the second HH number field.

4.After pressing the ENTER button to set the last HH field, the OFF Time infor- mation is saved.

Entering a PIN Code for the First Time

Setting Up PIN Code

A PIN Code can be programmed into the G1 to protect the settings from inadvertently being changed by unau- thorized users.

1.Press the UP ARROW button for 10 seconds.

The LED next to the LOCK ICON on the dis- play lights, indicating you have entered the PIN Mode.

2.The word OFF appears in the display. Press the UP or DOWN ARROW button to change this to ON.

3.Press the ENTER button to enter the PIN Code.

4.The cursor automatically is positioned to entered the first character of the PIN Code. Use the UP and DOWN ARROW buttons to move up

and down through the numbers 0-9 until the first number in the PIN code is displayed in the field.

5.Press the ENTER button to set the num- ber. The cursor automatically moves to the next number field.

6.Repeat steps 4 and 5 for each PIN Code prompt field.

7.Press the ENTER button to save the PIN Code and exit Advanced Setup.

Entering Advanced Setup

Press the UP ARROW button for 10 sec- onds.

If the G1 was previously set up to require a PIN Code, the LED next to the LOCK ICON lights, indicating a PIN Code is required.

1.The cursor is automatically positioned to enter the first character of the PIN Code. Use the UP and DOWN ARROW buttons to move up

and down through the numbers 0-9 until the first number in the PIN code is displayed in the field.

2.Press the ENTER button to set the num- ber. The cursor automatically moves to the next number field.

3.Repeat steps 1 and 2 for each PIN Code prompt field.

If the PIN Code you entered is correct, the G1 will be in the Advanced Setup option used to change the PIN Code.

A1 - Changing PIN Code .

To change a PIN Code, follow instructions for Entering a PIN Code for the first time.

Run Mode

Time Control

After setup is complete, the G1 automatically begins to run the OFF Time sequence.

This count down is in hours.)

???When the OFF

(Notice the dot below ON flashes on the display.)

???When the ON Time count reaches zero, the pump shuts off again and the system again runs OFF Time cycle and the OFF Time LED flashes again.

This sequence repeats itself until the device is reprogrammed or a Low Level Fault occurs.

???If power to the pump is lost during a lubrication cycle, when power is restored the pump will resume the cycle with the same amount of time remaining in the cycle as when the power was lost.

Run Mode

Low Level

Pumps equipped with low level detection will stop when the fluid level is sufficiently low to trigger the low level fault.

???The LED next to the LOW LEVEL

ICON on the display flashes.

Add lubricant to the pump. See Loading Grease instructions, page 19 or Filling Oil Unit, page 20.

???After lubricant is added, press the RESET button to clear the fault.

NOTE: For higher viscosity fluids it may be necessary to clear the low level fault prior to filling the pump. You can then press the Manual Start button to start the pump during the fill.

Manual Run Cycle

To run an extra (non-programmed) lubrica- tion cycle, push the Manual Start button.

NOTE: An Illuminated Remote Run Button

Kit: 571030, 571031 for starting a manual run cycle remotely if used in conjunction with a 5-wire CPC cable, is available from Graco. Contact your local Graco distrib- utor or Graco Customer Service for additional informa- tion about these kits.

41

Follower Plate Models Only

40a

15

67

3 37

31

66

Low Level Oil Models Only

30

35

57 271

60

16

13

14

13

1

17 3

33

23

Parts

Parts

???Replacement Danger and Warning labels, tags and cards are available at no cost.

??? Also order Ref 31 and Ref 34.

??? Also order Ref. 57 when ordering this part.

Pressure Relief Valves

Important Information regarding Pressure Relief Valve 16C807.

Pressure Relief Valve 16C807 can only be used on the G1 and G3 Pumps. It is not intended for use with any other products.

Parts

Fuses

Installation and Repair Kits

2x ?? 0.366 inch

9.3 mm

0.708 inch

18.0 mm

3.740 inch

95.0 mm