Graco Dyna-Star 77X202 User manual

3A3956C
EN
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
E
D
C
F
B
H
J
K
L
A
M
N
P
R
S
T
UV
C1
ti28534a
G

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
V
Y
Z
Z1
W
AA
P
R
BB

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
H
J
B
A
C
D
F E
G
KL
M
N