Commissioning & Troubleshooting

Series Parallel
Series Progressive

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Commissioning – Purge Air
After filling the pump reservoir run the pump to bleed air in the supply lines.

Then the Branch Supply Lines can be bled and finally the Feed Lines to the
bearings can be bled.

On Injector systems the Zerc fitting can be used to bleed the Feed Lines.

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 Commissioning – Pump Running Time
In centralised lubrication systems the metering devices are selected based upon the ratio between
the different bearing sizes hence it is the pump running time that is varied to set the lube volume.

In progressive systems if a cycle switch is present then the pump will be set to run for the number
of cycles that is required to give the volume for each lube event. E.g. of a CSP block has 0.2cc
output per cycle and the bearing requires 1cc then 5 cycles are required.

If a cycle switch is not present then the pump ON time must be set to provide sufficient volume.
This can be worked out as follows:

Total Volume per Lube Cycle (cc) / Pump Output (cc / min) = Running Time (min)

Because Injectors use three times their output volume the running time of the pump is based upon
visually verifying that each of the injectors has fired (by looking at the pin cycle). The run time is
increased to allow time for all of the injectors to complete their cycle.

For both systems additional time is added to allow for the higher viscosity of the grease when the
ambient temperature is cooler.

3
Commissioning – Injectors - Pressure Switch
The pressure switch is factory set for a nominal value that should be fine.

If it is located close to the pump however it may need to be set above the
nominal 2400psi (1800psi minimum for injectors to operate) in order to
overcome line losses along the circuit.

If this is the case then these are the steps to follow:

Steps: Adjustment inside

1. Turn the adjusting screw all the way in to
set the switch at near it’s maximum
setting.
2. Run the system at the desired pressure by
looking at he system pressure on the
gauge.
3. Gradually turn the adjusting screw until
the micro switch closes and shuts off the
motor.

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 Commissioning – Injectors - Grease Flow Rate
The pressure switches are not always located at the end of the line as theoretically
suggested. This means that the pressure switch can be activated before the last injector
has had time to fire.
-> The Speed and pressure of pump should be adjusted so that the grease has enough
time to flow through the system before building a back pressure to throw the pressure
switch.

Steps: HDS EDS

1. Run system and watch each of the
injector indicator pins fire.
2. If the pressure switch shuts the
pump down before the last injector
fires, reduce the grease flow rate.
3. Run the system again.
4. Continue to adjust the flow /
pressure until all injectors have
fired.
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 Troubleshooting – Pumps - Material Flow
The material flow / pressure on EDS pumps and Pneumatic FireBall pumps can be
tested the same way as any other priming piston grease pump.

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Troubleshooting – Pumps - Material Flow
G3 pumps have a positive displacement element driven by
a worm gear driven cam. This means they do not like to
run backwards. If the wiring is installed backwards then
the motor will be overloaded and burn out.

The element can be removed and inspected.

This is a wearing part.

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 Troubleshooting – Pumps - Electrical
The inputs and outputs of the G3 and GLC controllers can be
tested electrically using the standard tests:

• DC Voltage (for Vent Valve output and alarm outputs)

• Continuity (for Pressure Switch and Cycle Switch inputs)

If there are any issues with the G3 control

panel such as erratic . It can be replaced
however it is important to get all three parts.

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Troubleshooting – Controllers – Alarms
Alarms can be either Warnings or Faults on G3 units.
GLC2200 shows alarms only.

Each fault can have many causes.

Controller Fault – Er:Pr - Pressure switch did not activate

in specified time:

Blocked line, Leaking line, Pressure Switch…etc.
Controller Fault – Er:Cy - Cycle Switch did not activate in
specified time:
• Blocked line, Leaking line, Cycle Switch …etc.
Controller Fault – Er:LL – Low Level detected
• Lubricant low or LL switch issue.
There is a micro switch inside the Low Level
paddle. This can sometimes be faulty.

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Troubleshooting – Progressive – Blocks
• Minimum three working sections.
• All outlets must be connected to
lube points or if not then cross
ported to other working sections.
• Foreign matter can block pistons
from cycling. -> Flush blocks and use
an inline filter.
• Blocks can be serviced when leaking.

10
Troubleshooting – Progressive – Broken Line
Broken lines cause material wastage and environmental concerns.

If a line breaks down stream on a system with either a pressure or cycle switch
fitted then the controller will most likely time out and alarm when the preset
maximum lube cycle time is exceeded. If the system is run by time only then
visual checks are the main means of identifying this type of fault.

Graco does produce a broken line indicator that can be fitted with a switch to
alert the control system that there is an issue.

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 Troubleshooting – Progressive – Blocked Line
1. Make a visual inspection of the system. Check for crushed lines or improper divider valve
installation.
2. Verify that each divider valve outlet required to discharge lubricant can do so and that no pipe
plugs have been installed in an outlet designed to serve a bearing or another divider valve.
3. Use a manual pump with a gauge. Fill the pump with clean, filtered lubricant. Connect the
manual pump to the inlet of the master divider valve and slowly operate pump. If system will
not cycle freely, below 1500 psi, then increase the pressure to 2000 psi:
a) If an indicator accessories are fitted then it will indicate the blockage is down stream of
that accessory.
b) If an indicator accessory is not fitted then sequentially remove one indicator port plug at a
time. If the block cycles then the blockage is downstream of that point.

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Troubleshooting – Progressive – Electrical
Cycle Switches – Inductive
Can be tested with metallic objects such as a screwdriver.
Some may have 3 Wire connection. These require power to switch to operate.
Pwr, Sig, Gnd.

Cycle Switches - Mechanical

Dry contact switch. Close switch manually and test for continuity.
Test at pump by closing contacts.
Use visual pin indication so pin movement can be observed.

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Troubleshooting – Injector – Electrical
Pressure Switch
Generally tested by swapping out with another
pressure switch.
Gauge in system used to show actual pressure.
Controller can be tested by bridging contacts
to emulate switch operation.

Example from G3 pumps shown opposite

Vent Valve
Solenoid can be tested using external DC
power. Listen for ‘click’ of magnet.
Internal pressure relief valve components can
be checked for blockages. Ensure ball & seat
free from debris.
Signal from controller tested by DC Voltmeter.

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