Graco 308950 Operation manual

308950
Rev. B
First choice when
quality counts. t
8852A
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
See system manual 309015.
For Controlling and Monitoring Automatic Lubrication Systems
Lubrication Controller, 24V
Part No. 115123
This Lubrication Controller is designed to control and monitor most single-line parallel automatic lubrication sys-
tems. All configuration parameters are electronically stored in a System Set-Up Menu and a Time Menu
(see page 7), which eliminates the need to set dip switches or jumpers.
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Codes 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit 241574 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 10. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 12. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 12. . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
C3001IE

2 308950
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious inju-
ry or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
EQUIPMENT MISUSE HAZARD
Disconnect the power before servicing and before you remove the cover.
Do not touch electrical components inside the Lubrication Controller; you could get an electric
shock or damage the circuits.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories. Modifying
parts can cause a malfunction and result in serious bodily injury.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Connect to a proper electrical power source. See the Technical Data section on page 10.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
Use only alarm and control devices that are compatible with the electrical requirements of this
unit.
WARNING
INSTRUCTIONS

3308950
Installation
Typical Installation
The installation shown in Fig. 1 is only a guide for selecting and installing system components. Contact your Graco
distributor for assistance in planning a system to suit your needs.
LowReservoir
LevelSwitch
Userprovided
PressureSwitch
ForSystem Control
RemoteAlarmDevice
(Light or Horn)
Userprovided
Controller
Capabilities
A
KEY
AMain air supply
BFilter/Regulator/Lubricatorassembly
B1 Filter
B2 Regulator
B3 Lubricator
CAir solenoid valve
DPump module
EIgnition switch
GHigh-pressure lubricant supply lines
HInjector banks
JLubrication controller
B1 B2 B3 C
D
GHH
J
8853A
E
Fig. 1
Optional1 amp
fused line for Re-
moteAlarmDevice

4 308950
Installation
Installing the Lubrication Controller
CAUTION
This Lubrication Controller is not designed to be
operated in a caustic environment.
1. Select a flat surface upon which to install the
Lubrication Controller, and drill mounting holes
according to the Mounting Hole Layout on
page 10.
CAUTION
Use only the pre–drilled holes under the cover fas-
teners to mount the timer. Failure to use the desig-
nated mounting holes could cause circuit board
damage.
2. Remove Lubrication Controller cover, and secure
the junction box using four #6 screws (not pro-
vided).
CAUTION
Do not ground any lead for the pressure switch or
the low level switch. Circuit board damage may
result.
3. Connect solenoid valve leads to terminals 4(–) and
6(+) (output).
4. Fig. 2. Step optional for use of external alarm.
Terminals 7 and 8 are a normally open, voltage-
free switch, available as a switching device for an
external alarm circuit. Connect fused (+) power
supply (not supplied) to terminal 8. Connect termi-
nal 7 to external alarm. Ground external alarm to
complete circuit
Fig. 2 8855A
24
24
5. This step is optional.
Connect terminals 9 and 11 to a normally-open
pressure switch installed in system lubricant
supply line for pressure-controlled system shut-
down.
NOTE: The pressure switch, upon detecting the
preset pressure, will send a signal to the Lubrica-
tion Controller to deactivate the air solenoid valve,
which will deactivate the pump.
6. This step is optional.
Connect terminals 12 and 13 to a normally-open
low-level switch (user provided).
NOTE: Upon detection by a low-level sensor, the
Lubrication Controller will activate the alarm condi-
tion.
CAUTION
If using the low level indication feature, the lubrica-
tion controller will remain in alarm mode and will not
function until the low level switch is opened by refil-
ling of the fluid reservoir. Failure to correct the low
level condition will result in interruption of the auto-
matic lube system which could lead to premature
bearing failure.
7. This step is optional.
Connect terminals 14 and 15 to a normally open
switch. Closing of the switch will suspend Lubrica-
tion Controller operation. Reopening of the switch
will resume Lubrication Controller function from the
point at which operation was suspended.
WARNING
AUTOMATIC SYSTEM ACTIVATION
Do not connect power to timer if the pump
power supply is on, unless activation of the
automatic lubrication system is intended.
This device is an automatic timing device
that activates the output circuit (air
solenoid valve) upon power connection or
upon exit of the programming function.
Ignoring this warning could lead to serious injury
including fluid injection and amputation due to
activation of connected system components.
8. Connect the power leads from an isolated power
supply. Connect terminal 3 to the negative (–) lead
(ground), and connect terminal 2 to the positive (+)
lead.
9. Replace the Lubrication Controller cover.

8855A
8854A
Black indicates not used
Bottom
Top
See diagram below for
terminal identification
Optional Circuit (if using
remote external alarm)
24
5308950
Installation
Electrical Connections and Circuit Details
WARNING
ELECTRIC SHOCK HAZARD
Before you install or remove the
Lubrication Controller from the system,
disconnect and isolate all power
supplies.
CAUTION
110 volt and 220 volt power is not supported at this
time.

6 308950
Setup
Keypad and Display
The keypad and display are shown below with explanations.
TIME button
TIMER light
Display
UP button
DOWN button
RESET button
POWER light
PUMP ON light ALARM light
LOW LEVEL light
INDICATOR lights
8858A
PUMP ON light: Indicates that the Lubrication Controller is in the Pump On mode, and the device (air solenoid
valve) connected to terminals 4 and 6 should be receiving power.
Display: TIMER light on: Display indicates time remaining in hours and minutes until the next Pump On cycle.
PUMP ON light on: Display indicates time remaining in minutes and seconds in the Pump On cycle.
ALARM light on: Display indicates alarm codes (see page 8).
INDICATOR lights flashing: Display indicates that the Lubrication Controller is counting down to
the next Pump On cycle.
INDICATOR lights steady: Display indicates that the Lubrication Controller is in Suspended
mode, activated by contacts 14 and 15 being close-circuited.
TIMER light: Indicates that the Lubrication Controller is in Timer mode.
UP button: For toggling between options in the System Set-Up Menu. Press this button and the DOWN button at
the same time to enter the System Set-Up Menu.
TIME button: For advancing to the next option in the Time Menu.
DOWN button: For adjusting settings in the Time Menu. Press this button and the UP button at the same time to
enter the System Set-Up Menu.
POWER light: Indicates that power to the Lubrication Controller is on.
RESET button: For resetting an alarm malfunction. Resets to the start of a lube cycle –– pushing this button
activates Lubrication Controller to open solenoid and start pump. Will activate a manual lube cycle and resets
pause interval.
LOW LEVEL light: Indicates that the reservoir fluid level is low.
ALARM light: Indicates that an alarm is activated.

7308950
Setup
WARNING
AUTOMATIC SYSTEM ACTIVATION
Do not connect power to timer if the pump power supply is on, unless activation of the automatic
lubrication system is intended. This device is an automatic timing device that activates the output
circuit (air solenoid valve) upon power connection or upon exit of the programming function.
Ignoring this warning could lead to serious injury including fluid injection and amputation due to
activation of connected system components.
System Set-Up Menu
The System Set-Up Menu is used to configure the type of pump and automatic lubricating system that is connected
to the Lubrication Controller. The modes in the System Set-Up Menu progress in the order shown in the table
below.
To access the System Set-Up Menu, press the UP and DOWN buttons simultaneously, and hold them down for two
seconds.
Parameter Description Screen Display Operation
Lubrication system
Pressure-switch-controlled
on single-line systems Press the UP button to toggle between
hi
y
type No pressure-switch-control,
just timer
gg
the two options.
Press the TIME button to accept the change. Press the RESET button to cancel the change.
Time Menu
The Time Menu is used to adjust the Pump On cycle and Pause Interval . The modes in the Time Menu progress in
the order shown in the table below.
To access the Time Menu, press and hold the TIME button for two seconds.
Parameter Description Screen Display Operation
Pump On time Indicates the minimum
Pump On time in
minutes :seconds
Maximum: 59:50
Minimum: 00:10
Press the UP and DOWN buttons to
adjust the setting.
Press and hold the TIME button for two seconds to advance to the next option.
Pause interval Indicates the Pause
Interval between lubrication
cycles in hours :minutes
Maximum: 99:59
Minimum: 00:01
Press the UP and DOWN buttons to
adjust the setting.
Press and hold the TIME button for two seconds to return to normal operating mode.
PUMP ON light
flashing
TIMER light
flashing

8 308950
Operation
1. Connect power to Lubrication Controller.
WARNING
AUTOMATIC SYSTEM ACTIVATION
Do not connect power to timer if the pump
power supply is on, unless activation of the
automatic lubrication system is intended.
This device is an automatic timing device
that activates the output circuit (air
solenoid valve) upon power connection or
upon exit of the programming function.
Ignoring this warning could lead to serious injury
including fluid injection and amputation due to
activation of connected system components.
2. See Setup on page 7 for Lubrication Controller
programming.
3. Open air supply to air solenoid valve.
4. Activate power to Lubrication Controller to initiate
Pump On cycle. Ensure that PUMP ON light and
POWER light are on and the pump is operational.
5. Ensure that POWER light and TIMER light are on
after Pump On cycle is complete.
Lubrication Controller will automatically activate
the system at programmed intervals.
6. Power will be removed from properly wired system
upon turning off ignition key.
7. To disable automatic lube system, turn off air
supply to solenoid and/or pump.
Alarm Codes
The Lubrication Controller self diagnoses when it is powered up, and alarm codes are shown in the display during
fault conditions. These alarm codes are explained in the table below.
NOTE: for automatic lube system troubleshooting, see manual 309015.
Alarm Code Description Corrective Action
A01 No parameters set. Set the parameters of the system. See Setup
on page 7.
A02 Level of lubricant is low in the supply container.
Lubrication Controller will not function until the
fluid reservoir is filled.
Add lubricant to the supply container.
NOTE: This alarm requires that your system
has a low-level switch installed.
A04
(PSI mode
only)
The system pressure was already high before
the start of the cycle. Check pressure switch and replace if neces- sary.
Check to see if system vents properly.
A05
(PSI mode
only)
PSI mode: The system did not achieve pres-
sure during the specified cycle times.
1. Pump On setting for system is too short.
2. Out of lubricant.
3. Broken supply line.
4. Injector malfunction.
5. Pump malfunction.
6. Vent valve malfunction.
Check for and correct lubricant leakage from
any loose fittings or from the pump.
Adjust setting as appropriate. See Time Menu
on page 7.
Fill reservoir.
Fix or replace.
Replace.
Refer to Pump Manual 308883.
Fix or replace.

9308950
Troubleshooting
Description Problem Solution
Timer fails to activate sole-
noid No power supplied to solenoid
Solenoid faulty
Timer faulty
Low Level alarm
Power light off: timer is not receiving power.
Verify connections and verify power supply
Power light on: verify solenoid connections
Replace solenoid
Replace timer
Refill reservoir
Pressure switch fails to shut
down system Pressure switch incorrectly wired
Pressure switch faulty
Timer faulty
Verify proper connections
Replace pressure switch
Replace timer
Accessories and Kits
Repair Kit 241574
Repair Kit 241574 is available. It contains two junction
box connectors and six rubber grommets, as shown.
8856A
24V Air Solenoid 114488
9008A
3/8” npt (3)
Manual
Activation
Button
Pressure Switch 115124
1/4” npt(f)
9146A

10 308950
Technical Data
Input Contacts
Power 24V D.C.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power consumption 20 Watts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control input (optional) Normally open pressure switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication level (optional) Normally open level switch, closes upon low level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outputs
Air solenoid valve (pump control) 24V D.C.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm switch, normally open (optional) Voltage-free contact, 250V maximum, 1 amp. . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection grade IP55, Nema 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating temperature range –13F to 131F (–25C to 55C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions
8852A
5.2 in.
(132 mm)
5.2 in.
(132 mm)
2.4 in.
(60 mm)
8852A
Mounting Hole
Layout
8857A
3.74 in.
(95 mm)
Drill four
0.14-in.
(3.5-mm)
holes. 3.74 in.
(95 mm)

11308950
Notes

12 308950
Graco Standard Warranty
GracowarrantsallequipmentmanufacturedbyGracoandbearingitsnametobefreefromdefectsinmaterialandworkmanshiponthe
dateofsalebyanauthorizedGracodistributortotheoriginalpurchaserforuse. Withtheexceptionofanyspecial,extended,orlimited
warrantypublishedbyGraco,Gracowill,foraperiodoftwelvemonthsfromthedateofsale,repairorreplaceanypartoftheequipment
determined by Graco to be defective. This warranty applies only when the equipment is installed,operated andmaintained in accor-
dance with Graco’s written recommendations.
This warranty does not cover, and Graco shall notbe liable forgeneral wearand tear, or any malfunction,damage or wearcaused by
faultyinstallation,misapplication,abrasion,corrosion,inadequateorimpropermaintenance,negligence,accident,tampering,orsub-
stitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verificationof theclaimeddefect. Iftheclaimed defect is verified, Gracowillrepairor replace free of chargeanydefectiveparts. The
equipmentwillbereturnedtotheoriginalpurchasertransportationprepaid. Ifinspectionoftheequipmentdoesnotdiscloseanydefect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES,EXPRESSOR IMPLIED, INCLUDINGBUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’ssoleobligationandbuyer’ssoleremedyforanybreachofwarrantyshallbeassetforthabove. Thebuyeragreesthatnoother
remedy(including,butnotlimitedto,incidentalorconsequentialdamagesforlostprofits,lostsales,injurytopersonorproperty,orany
otherincidentalorconsequentialloss)shallbeavailable. Anyactionforbreachofwarrantymustbebroughtwithintwo(2)yearsofthe
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
withaccessories,equipment, materialsor componentssoldbutnotmanufacturedbyGraco. Theseitemssold,butnotmanufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of theirmanufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
Thepartiesacknowledgethattheyhave requiredthat thepresent document,aswellasalldocuments,noticesandlegalproceedings
enteredinto,givenorinstitutedpursuantheretoorrelatingdirectlyorindirectlyhereto,bedrawnupin English. Lespartiesreconnais-
sentavoirconvenu quelarédaction duprésentedocument seraenAnglais, ainsiquetous documents,aviset procéduresjudiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Number
TO PLACE AN ORDER , contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–533–9655 Toll Free
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit
Foreign Offices: Belgium, England, Korea, France, Germany, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
www.graco.com
PRINTEDIN USA 308950 May 1999, Revised May 1999