Graco Dyna-Star HP User manual

Dyna-Star®HP or HF Pump
Low Level Indicator Kit; Dip
Stick Kit 332515F
EN
Provides a visual reference of remaining fluid level in a tank / reservoir used with the
Dyna-Star HP or HF pump. Low Level Indicators equipped with a user supplied alarm will
also provide an audible and/or visual notification of a low fluid level. For professional use
only.
Low Level Indicator Part No: 77X522
Includes sight glass, electric low level switch and cable. Requires follower plate. Cannot be used with Auto-Fill®Shut Off.
Dip Stick Part No: 77X530 - 90#; 77X531 - 60#
Cannot be used with a follower plate or Auto-Fill Shut Off.
Important Safety Instructions
Read all warnings and instructions in this
manual and in the Dyna-Star HP or HF Pump
instruction manual. Save all instructions.
Part No. 77X522 Part No. 77X530 or 77X531

Installation
Warnings
See the Dyna-Star HP and HF Pump Instruction manual
for additional warnings.
Pressure Relief
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. See FIG. 1.
Installing Low Level Indicator
1. Disconnect Dyna-Star pump from main power
source.
2. If unit has already been in service, relieve pressure
(see Pressure Relief procedure, page 2).
3. Fill reservoir with grease to raise follower plate (if
installed) to an easily accessible level.
NOTE:
• Installing the follower plate and low level will be
easier if the reservoir has been filled with
grease first.
• If a follower plate is not pre-installed, fill tank at
least half full.
4. Remove plug (a) from cover (b). Discard plug, you
will not reuse it (FIG. 2).
5. Loosen bolts (c) and remove cover (d) from
Dyna-Star pump (FIG. 3).
SKIN INJECTION HAZARD
High-pressure fluid from dispense 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.
Follow Pressure Relief Procedure in this manual,
when you stop dispensing and before cleaning, check-
ing, or servicing equipment.
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. 1
FIG. 2
a
b

6. Remove screws (e) and washers (f) holding
Dyna-Star Pump to reservoir cover (b) and remove
pump from cover (FIG. 4).
7. Remove the screws (g) (holding the reservoir cover
(b) to the reservoir (h) (FIG. 5).
8. (If previously installed) remove follower plate from
inside reservoir.
9. Determine the correct cable length to use for your
pump reservoir.
• Short cable is used with 60# reservoirs.
• Long cable is used with 90# reservoirs.
Remove and discard the cable you are not using and the
Notice label attached to the cables.
10. For easy wiring, make sure the DIN connector is
facing out (FIG. 6). Feed the low level cable (j)
through accessory hole (aa) in the reservoir cover
(b). Wrench tighten low level in place.
FIG. 3
FIG. 4
d
c
e
f
b
FIG. 5
NOTICE
Failure to use the correct cable length could result in
inaccurate level indication and low level shutdown.
FIG. 6
g
b
h
j
aa
b

4332515F
11. Remove one of the screws (k) from the follower
plate (m) (FIG. 7).
12. Install screw (k) through the hole (n) in the cable
bracket (p) located at the end of the low level cable
(j) and then through the screw hole (r) in the follower
plate (m) (FIG. 7). Tighten screw securely.
NOTE: Cable bracket (p) is slightly bent. Be sure to
install so the bracket will sit flat against the surface
of the follower plate.
13. Install follower plate (m) on top of grease inside res-
ervoir (h) with the cone side facing up. Press fol-
lower plate firmly into grease to remove all air
pockets.
14. Place reservoir cover (b) on top of reservoir (h).
NOTE: When reservoir cover (b) is correctly
installed on reservoir (h), the low level cable (j)
(installed between the low level indicator and fol-
lower plate (m) will be aligned in a straight and verti-
cal line as shown in FIG. 8.
15. Replace and tighten screws (g) securely (FIG. 9).
FIG. 7
k
j
p
n
r
m
FIG. 8
FIG. 9
m
h
b
j
g

Installation
332515F 5
16. Slide pump down-tube through hole in the center of
the reservoir cover (b) and hole in the center of the
follower plate (m) as shown in FIG. 10.
NOTE: When pump is correctly installed, the breather (t)
will be below the control box (s) as shown in FIG. 11.
17. Replace screws (e) and washers (f) and wrench
tighten securely (FIG. 12).
18. Reinstall cover (d) using bolts (c) (FIG. 13). Use a
wrench to tighten bolts securely.
FIG. 10
FIG. 11
b
m
t
s
FIG. 12
FIG. 13
e
f
d
c

Installation
6332515F
External Alarm or Warning Light (Optional)
An external (user supplied) alarm or warning light can
be added to the Low Level Indicator to provide an audi-
ble or visual signal in a low level situation.
1. Connect the DIN connector on the Low Level Indica-
tor to the (user supplied) alarm device. Connection
is made to PINS 1 and 3 of the DIN, Form “A” Field
Wireable Adapter. See FIG. 14.
2. Connect Dyna-Star pump to main power source.
3. Start system following pump start up procedure
included in the Dyna-Star HP or HF Pump Manual
provided with your system.
NOTICE
To avoid premature failure and the loss of fluid/low
level indication:
• Do not exceed the rating of the Low Level Sen-
sor Switch by connecting excessive lights or
audible signals.
• Level Sensor Switch is rated for a maximum of
32 VDC and 10 Watts. Maximum switch current
is 0.4 AMPS.
FIG. 14

Low Level Visual Indication Sight Glass
332515F 7
Low Level Visual Indication Sight Glass
Normal Level Mark (FIG. 15) - Red rod is completely
covered by the green tube (G) and no red is visible in
sight glass. This appearance indicates that the lubrica-
tion supply container has sufficient material. No addi-
tional lubricant needs to be added.
Low Level Range (FIG. 16) - Red rod (R) is partially
covered by the green tube (G). Some red is partially vis-
ible at the top of the sight glass. This appearance indi-
cates that the lubrication supply container is
approaching the low level mark and needs to be refilled.
Low Level Mark (FIG. 17) - Red rod (R) is completely
visible with green tube (G) at lowest level. This appear-
ance indicates that the main lubrication supply container
is low and needs to be refilled.
For models equipped with a (user provided) external
alarm, when the fluid has reached this low level mark,
the sensor switch closes, activating the alarm.
FIG. 15
FIG. 16
sight
glass Green (G)
sight
glass
Red (R)
Green (G)
FIG. 17
sight
glass Green (G)
Red (R)

Dip Stick Installation
8332515F
Dip Stick Installation
1. Remove plug (a) from cover (b). Discard plug, you
will not reuse it (FIG. 18).
2. Slide dipstick through hole (aa) in cover (b) and into
reservoir (FIG. 18 and FIG. 19). Wrench tighten it in
place. 3. To determine the level of the fluid remaining in the
reservoir, loosen and remove dip stick (c) from res-
ervoir cover (b).
4. Use a clean rag to wipe oil/grease from end of dip
stick (c).
5. Insert dipstick (c) through hole (aa) in cover (b) as
far down as it will go and then remove it again. Visu-
ally inspect level of oil/grease remaining on dip stick.
FIG. 18
a
aa
b
FIG. 19
c
b
aa

Low Level Indicator Technical Data
332515F 9
Low Level Indicator Technical Data
Dip Stick Technical Data
Low level sensor switch Normally open sensor switch, closes upon low level
Operating temperature range -50°F to 150°F (-45°C - 65°C)
Electrical Ratings
Switching Power 10 Watt Max.
Switching Current 0.4A-Max.
Switching Voltage 5 - 32 VDC
Contact Resistance 0.150 Initial Ohms - Max.
Body Thread 3/4 inch npt(m)
Wetted Parts
Cable Nylon coated stainless steel
Crimp Tab Stainless steel
Body Thread 3/4 inch npt(m)
Wetted Parts Zinc plated steel