Graco Dyna-Star 77X202 User manual

3A3956C

Instructions

Dyna-Star®HP

Pump System

Provides lubricant flow and pressure to operate a single line parallel automatic lubrication

system. For automatic lubrication systems only.

Not approved for use in European explosive atmosphere locations.

Models

77X202 - 60 lb

77X203 - 90 lb

24VDC, Injector module with pump, tube-in-tube, vent

valve, auto-fill shutoff, low level, 60 lb. or 90 lb. reservoir.

3500 psi (24.1 MPa, 241 bar) Maximum Working Pres-

sure

5000 psi (34 MPa, 344.7 bar) Maximum Refilling Inlet

Pressure

Related Manuals

Important Safety Instructions

Read all warnings and instructions in this

manual, the Dyna-Star HP and HF Pump

instruction manual and all related component

manuals (listed below). Save all instructions.

Manual Description

332514 Dyna-Star HP and HF Pump

332518 Dyna-Star HP and HF Auto-Fill Shut

Off Kit

332519 Dyna-Star HP Vent Valve Kit

333393 Fill Valve

334998 Power Cable Kit

334999 Cable Harness Kit

3A2960 GLC2200 Lubrication Controller

Warnings

23A3956C

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.

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

3A3956C 3

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 com-

ponent. See Technical Data in all equipment manuals.

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

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information

about your material, 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 manu-

facturer’s replacement parts only.

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

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 equipment,

follow the Pressure Relief Procedure and disconnect all power sources.

BURN HAZARD

Equipment surfaces and fluid that is 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. 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 manufacturer.

Warnings

43A3956C

Typical Installation

Systems with Pressure Relief Valve in the Refilling Line

The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor

for assistance in planning a system to suit your needs.

NOTE: The remote filling station pump stalls (dead-heads) when the reservoir is full. If the pump does not stall

(dead-head) there is a leak in the system.

FIG. 1

ti28534a

Warnings

3A3956C 5

Key:

A Lubricant outlet connection (marked with an “0”)

B Pump

C Ignition switch

C1 Fuse

D High-pressure lubricant supply lines

E Injector banks

F Lubrication controller

G Fill port (not used with Auto-Fill Shut Off)

H Overflow port (not used with Auto-Fill Shut Off)

J Breather

K Reservoir

L Vent Valve

M Motor

N Fluid overflow container

P Pump - remote filling station

R Reservoir - remote filling station

S Auto-Fill Shut Off

T Low Level Sensor

U Pressure Relief

V Supply Hose

Warnings

63A3956C

Typical Installation

Systems with Fill Valve in the Refilling Line

The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor

for assistance in planning a system to suit your needs.

NOTE: The remote filling station pump stalls (dead-heads) when the reservoir is full. If the pump does not stall

(dead-head) there is a leak in the system.

Key:

P Pump - remote filling station

R Reservoir - remote filling station

V Supply Hose

W Pressure Relief Line

Y Instruction Label

Z Fill Valve

Z1 Pressure Relief Knob

AA Refilling Line

BB Filter

NOTE: The components highlighted in FIG. 2 identify the

unique features in a Fill Valve installation. See Typical Installa-

tion on page 4 for a complete list of the other system compo-

nents.

Install the fill valve (Z) in an easily accessible location

between the remote fill station pump (P) and Auto-Fill Shut Off

Valve (S).

The fill valve is used to relieve pressure in the refilling line and

to reset the Auto-Fill Shut Off.

FIG. 2

Installation

3A3956C 7

Installation

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 pump outlet fitting to

slowly loosen fitting only until fitting is loose and no

more lubricant or air is leaking from fitting as shown in

FIG. 3.

Grounding

System Configuration and Wiring

NOTE: Cable wiring harness kits are available from

Graco. See Parts page 20 for a complete list of available

kits.

Fuses

NOTE: The pump is equipped with a 6-pin (4 pins are

used), M23 connector for use with Graco cable wiring

harness kit 77X546. See Parts page 20.

FIG. 4 shows the pump connections when used with

Graco Wire Harness 77X546. Also see pages 9 and 10

for connection details when a customer/user supplied

wiring harness is used.

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 Pro-

cedure when you stop dispensing and before clean-

ing, checking, or servicing the equipment.

FIG. 3

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 electrical current.

NOTICE

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

avoid equipment damage:

• Never operate the Dyna-Star Pump models 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 35A fuses.

Installation

83A3956C

Pump Connection with Graco Wiring Harness 77X546

Wire Connection Table

FIG. 4

See FIG. 5

Pin Wire Color Connection

1 Orange Signal +

2BlackPower-

4RedPower+

5 Blue Signal -

FIG. 5

Installation

3A3956C 9

User Supplied Wiring Harness

24 VDC With Signal Input

*A Vent Valve is only used in an injector-based system.

24 VDC With External Relay

*A Vent Valve is only used in an injector-based system.

FIG. 6: Pump control switch shown in signal mode

ti21392b

FIG. 7: Pump controls switch shown in power mode

ti21393b

Installation

10 3A3956C

Motor Control Board

Key

A + (Positive) Power Input

B - (Negative) Power Input

C Turn On Signal -

D Turn On Signal +

E Red (Fault) LED - Blinks type of fault (See Fault Table)

F Green (Power) LED -

•Blinks: Power ON, Pump running

•Solid: Power/Pump OFF

G Current Control Potentiometer (Minimum: Turn Knob

Counter-Clockwise / Maximum: Turn Knob Clockwise)

H Flow Control Potentiometer (Minimum: Turn Knob

Counter-Clockwise / Maximum: Turn Knob Clockwise)

J Pump Control Switch*

•PWR - Turns pump on when power is applied

•SIG - Turns pump on when voltage is applied to:

- SIG IN -

- SIG IN +

K Blue Motor Wire Connection

L Yellow Motor Wire Connection

M Green Motor Wire Connection

N J5 Connector - Motor Hall Cable Connector

*NOTE: Be sure power to pump is OFF before switching

between the PWR and SIG modes.

FIG. 8

F E

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