PDF - Groeneveld CPL Systems
Contents
1. 33 6 1 Electronic timer 34 6 2 Adjustment of the cycle time interval 34 6 3 Testing the electronic timer 35 6 4 Alarm signals 35 6 5 Technical data 36 Pneumatic impulse counter 37 7 1 Operation 38 Jud Setting the number of brake applications 39 7 3 Technical data 39 Metering units 41 8 1 Types of metering units 42 8 2 Operating principle 43 8 3 Phase A 43 8 4 Phase B 44 8 5 Phase C 44 Table of contents SINILNO2 dO 119V1 Single Line General Manual 9 Other components 45 9 1 Solenoid valve 46 9 1 1 Technical data 46 9 2 Pressure switch 47 9 2 1 Technical data 47 9 3 Reservoir2. 48 9 4 Follower plate 48 10 Refilling the reservoir 49 11 Maintenance 51 12 Fault diagnosis 53 Table of contents EG0102 Single Line General Manual J2Vdd d ff i fi L h Css GAOENEVELD Your efficiency is our challenge EG0102 Preface Single Line General Manual Preface This general manual is a description of the Singleline Automatic Greasing System The intention is to provide clients with an insight into how the system works what the possibilities are and briefly maintenance aspects Furthermore you will find the technical data of the various parts of the lubrication system in this manual The general manual can also be used as a user manual The manual is built up of different sections indicated by chapter numbers The numbering of pages and the images re starts with every new chapter In this manual the following pictograms are used to bring an item to the user s at tention or to notify the user ATTENTION Important supplementary information is provided for the user in the hopes of preventing errors from occurring WARNING This pictogram notifies the user when the danger of physical injury or severe damage by improper use should arise EG0102 Single Line General Manual
3. 1125 psi for an air pressure of 125 psi temperature range 13 F to 176 F NLGI 0 grease t sabs 475315 1852 bs Oil pumps maximum grease pressure 26 Pumps EG0102 Single Line General Manual 5 2 5 2 1 EG0102 Electrically operated gear pump Pump unit follower plate low level indicator switch pressure control valve connector fitting vent opening main pipe line connector pressure switch connection electro motor filler connector gear pump reservoir 2 9 16 7150 an O LI ZD Figure 5 2 Electrically operated pump Pumps 27 Single Line General Manual The gear pump 9 is activated by the electronic timer The lubricant will now be pumped from the reservoir 10 through the main pipe line 6 to the metering unit distribution blocks The pump remains in operation throughout the entire cycle pe riod This cycle or impulse period is 3 minutes when the standard version of the electronic timer is used The pump builds up the lubricant pressure during the cycle When the pressure reaches 838 psi the pressure control valve 3 opens lubricant is then no longer pumped into the main line but returns to the reservoir The pres sure is thus limited to 838 psi The standard version of the electrically operated pump is fitted with a pressure switch 7 If during the lubrication cycle the pressure does not rise above 588 psi the elect
4. 72 Ff A LA mun IA NOILDMNAOHGINI GROENF VELD Your efficiency is our challenge EG0102 Single Line General Manual This chapter is a short presentation of GROENEVELD Transport Efficiency and its products The chapter ends with some general remarks about the Singleline greas ing systems 1 1 GROENEVELD Transport Efficiency B V Investing in operational safety With this thought in mind GROENEVELD was founded in 1971 The present international network is administered from its head quarters in Gorinchem GROENEVELD strives for an expansion of its leading posi tion achieved by the company s solid image and customer oriented policy GROENEVELD employees form a team that works every day with great enthusiam and dedication for its customers Extensive automation makes a high working rate pos sible The ISO 9001 standard is the basis for the guaranteed quality of GROENEVELD products Frequent contact with clients and an extensive dealer network guarantee the good name of GROENEVELD We know what the entrepreneur needs today not a ready made product but a custom made solution for automation New technologies offer new applications Therefore GROENEVELD has a large bud get available for the development of new cost saving products Our Research and Development department not only collaborates with leading external organiza tions but also with leading manufacturers of
5. 7 Electronic timer does not a Fuse blown a Fit new fuse operate 8 Too much grease at all a System greasing fre b Reduce the greasing fre lubrication points quency does not corre quency Do not be too spar spond with vehicle ing it is better to grease operating conditions too much than too little 9 Alarm buzzer in elec a Grease level in the reser a Fill the reservoir see sec tronic timer sounds inter voir below the minimum tion 10 mittently a System not reaching a Top up the reservoir with working pressure grease and or repair the main pipe check the pump pressure with a manometer c No cycle time interval c Set a cycle time interval selected on the electronic on the electronic timer timer EGO102 Fault diagnosis 55 Single Line General Manual Notes 56 Fault diagnosis EG0102 Groeneveld Australia Pty Ltd 18 20 Mc Dougall Road P O Box 787 Sunbury Vic 3429 AUSTRALIA Tel 61 397 4099943 Fax 61 397 4099665 Groeneveld Belgium NV SA Industriezone Hogenakkerhoek Heirbaan 3 B 9150 Kruibeke BELGIUM Tel 32 3 8979860 Fax 32 3 8979861 Groeneveld do Brasil Ltda Rua Sabia 775 Moema 04515 001 Sao Paulo SP Brasil Tel 55 11 5052 5259 Fax 55 11 5052 7002 Groeneveld CPL Systems Canada Inc 8450 Lawson Road Unit 5 Milton Ontario LOT 0J8 CANADA Tel 1 800 263 1760 Fax 1 905 875 2125 Groeneveld Deutschland GMBH Bullermanshof 2B 47441 Moe
6. be rotated With a pneumatically operated impulse counter Fig ure 7 2 activation is through pulses from the pneumatic system before the relay valve The compressed air operates a piston which in turn rotates the operating cam After a preset number of pulses the operating cam opens the air valve through which compressed air passes to the pump The lubrication cycle then begins After a further number of pulses depending on the setting of the counter the pump is vented through the venting outlet R 38 Pneumatic impulse counter EG0102 007 Menuer nssi jo eeq Date of issue January 2004 Single Line General Manual 7 2 7 3 EG0102 Setting the number of brake applications Figure7 3 Setting the brake impulse The number of pulses required for the counter to activate the pump is set as fol lows e Remove the transparent cover e Setthe distance Figure 7 3 between the left hand side of the striker 1 and the head of the adjusting bolt 2 The distances equivalent to a specific number of pulses are shown on the transparent cover A feeler gauge 3 is fixed to the inside of the cover and can be used to set this distance The tool is marked with the number of pulses related to each thickness e Tighten the adjustment bolt lock nut 4 e Replace and secure the cover REMARK Setting the pneumatic impulse counter is easier when the pneumatic line is under pressure This moves the cam striker to the right so that
7. electronic timer sounds an alarm to indicate that the timer or greasing system is not functioning properly it is strongly advised to examine or have examined the greasing system and if necessary to make repairs If this is left too long damage can be caused to either the installation or the greasing system 6 5 Technical data cycle steps of 30 minutes intemals 0 5 5 h steps of 5 minutes steps of 30 minutes alarm built in buzzer internal relay 16A internal relay 16A 36 Electronic timer EG0102 Single Line General Manual PNEUMATIC IMPULSE COUNTER GAOENE VELD iima A _ ad a x x Mi Your efficiency is our challenge 37 Pneumatic impulse counter EG0102 Single Line General Manual 7 1 Operation solenoid valve screw for manual operation test compressed air connection pump connection venting outlet p 9 N gt Figure 7 1 Electrically operated brake impulse counter signal air screw for manual operation test compressed air connection pump connection venting outlet DDPUN Figure 7 2 Pneumatically operated brake impulse counter The pneumatic impulse counter starts the lubrication cycle after a set number of pulses The electrically operated counter Figure 7 1 is activated by an electric sig nal The solenoid valve of the pneumatic impulse counter is energized causing the operating cam to
8. reservoir can escape to the space above the follower piston 1 through the overflow port 12 and a channel in the guide rod 3 If the reser voir is inadvertently filled to a level above its maximum level this excess lubricant is also allowed to escape in this way EG0102 Single Line General Manual 5 3 2 Technical data Grease pump grease output cc min see remark ri 1500 max grease pressure psi content content reservoir litres content reservoir litres masters Du o x ps s a electrical connection 4 pin pin 2 minus pin 3 grease pressure switch pin 4 grease level switch lower psonn reena ye am ves ves ves e messed presreswich yes ves ves yes yes yo IEEE Lot zo to str sind to operating temperatures F O grease 00 000 or of 23 F 176 F LT grease operating temperatures below 5 F es 21 56 21 56 19 36 19 36 19 36 19 36 g lbs lbs lbs lbs lbs lbs REMARK The output of the pump is specified in cubic centimetres per minute If the greasing system is to operate properly however the pump should have supplied the total quantity of grease required by the system before 70 of the lubrication cycle has expired The length of the cycle must be set accordingly This will guarantee that the grease pressure reaches a value of at least 1176 psi and that the pressure switch in the pump will report this fact to the control unit If the c
9. sys tem is depressurized The metering units are then able to automatically refill themselves and are then after a minimum delay of 2 minutes ready for the next lubrication cycle 4 2 System with pneumatically operated pump and impulse counter As a rule trailers and semi trailers are equipped with a pneumatic brake impulse counter and not with an electronic timer or PLC This is because of a lack of a con tinuous electrical supply The standard version of the brake impulse counter is pneumatically operated and uses the air signal from the service line which is usually connected to the number 4 position of the trailer relay valve This position may differ in the different coun tries please contact your local dealer or GROENEVELD In certain situations the sig nal line can be too long as is the case with extended semi trailers Another relay valve is then installed in the fixed part of the semi trailer Alternatively an electrical version of the pneumatic impulse counter can be used which operates through the brake light circuit 18 System summary EG0102 Single Line General Manual 4 2 1 System with pneumatically operated impulse counter 7 LZ his pneumatic impulse counter 748 a aa CD VA Sle Ze Tn restrictor um signal line flow limiter iji Ia SY fru metering unit distribution block i H compressor HOE Figure 4 2 System with pneumatically operated impulse counter schematically The
10. vehicle air tank is connected to input P of the pneumatic impulse counter Al ways draw air from the auxiliary tank Port A on the pneumatic impulse counter is connected to the compressed air connection on the underside of the pump Port R on the pneumatic impulse counter is connected to the vent above the main piston The other connection on this double banjo union is an open vent EG0102 System summary 19 Single Line General Manual 4 2 2 System with electrically operated impulse counter electric signal if M a za BAD e I 7 metering unit distribution block ll i 9 Ha flow limiter i JE lt compressor a nmm Figure 4 3 System with electrically operated impulse counter schematically This corresponds broadly with that of a pneumatically operated impulse counter The signal impulse is derived from an electric signal 20 System summary EG0102 Single Line General Manual 4 3 EG0102 System with electrically operated pump fo oN electronic timer metering unit distribution block battery Figure 4 4 System with electrically operated pump schematically At a time set by the electronic timer or PLC a gear pump under the grease reservoir is started The lubricant is pumped from the reservoir via the main pipe to the me tering unit blocks The metering units then simultaneously allow a measured quan tity of lubricant to be pressurized to the points to be lubricated A pre
11. G0102 Single Line General Manual 6 3 6 4 EG0102 Testing the electronic timer The various electronic timer functions can be tested as follows Test 1 step switch test e This test checks the step switch contacts in all positions e Set the step switch to position test A e Activate the electronic timer by switching on the ignition e Press the test button e Wait for the audible alarm signal then release the test button e Within 5 seconds turn the step switch to the required interval time posi tion Each position produces a number of signals position 1 gives one sig nal position 2 two signals etc e The switch can be set to all positions positions test A and test B will not produce an alarm signal e End the test by switching off the ignition Test 2 accelerated cycle test e Set the step switch to position test A e Press and hold the test button e Switch the ignition on while still keeping the test button pressed in e The alarm signal buzzer will now sound The test button must be pressed as long as the alarm signal continues e Within 5 seconds of the end of the alarm signal turn the step switch to the required position e The electronic timer is now fully operational the time intervals are now 1 20 of their usual times e End the test by switching off the power supply Test 3 normal system test e Switch the ignition on e Press the test but
12. General Manual 7 TAN R Voy AZ Ji ya rn TO in C M Ss Single Line Automatic Greasing Systems North American Market EGO102 Your efficiency is our challenge All rights reserved No part of this manual may be copied and or published by means of printing photocopying microfilm or by any other means without prior written permission from Groeneveld This applies also to the drawings and diagrams appended Groeneveld reserves the right to change parts at any time without prior or direct notice to the customer The contents of this manual may also be changed without prior notice This manual applies to the standard version of the product Groeneveld cannot accept liability for any damage arising from the use of specifications other than that supplied You are requested to contact Groeneveld technical service for information concerning adjustment maintenance work or repairs that is not described in this manual Whilst this manual has been prepared with the greatest possible care Groeneveld cannot accept responsibility for any errors of the concequences of such errors Single Line General Manual EG0102 Preface eee 5 Introduction 7 1 1 GROENEVELD Transport Efficiency B V 8 1 2 GROENEVELD Greasing Systems 8 1 3 Single Line Automatic
13. Greasing Systems 9 Conversions sizes and weights 11 2 1 Sizes and weights conversions 12 22 Temperature conversions 13 Principle of operation 15 System summary 17 4 1 System with pneumatically operated pump and electronic timer PLC 18 4 2 System with pneumatically operated pump and impulse counter 18 4 2 1 System with pneumatically operated impulse counter 19 4 2 2 System with electrically operated impulse counter 20 4 3 System with electrically operated pump 21 4 4 System with electric plunger pump 22 PUMPS neskea mis dote eS See eee ieee eS ae ie 23 5 1 Pneumatically operated piston pump 24 5 1 1 Pump unit 24 5 1 2 Technical data 26 5 2 Electrically operated gear pump 27 5 211 Pump unit 27 5 2 2 Technical data 28 5 3 Electric axial plunger pump 29 5 3 1 Pump unit 29 5 3 2 Technical data 31 Electronic timer
14. ant will be pressed through the primary line to the distributors and consequently to the dos age metering units Each metering device then forces powered by the grease pres sure an exact amount of grease through the secondary lines to the grease points All metering units act simultaneously The amount of lubricant that goes to each of the grease points depends on the type of metering device installed A pressure control valve built into the pump unit maintains a constant pressure of 1500 psi in the system during the lubrication cycle i e while the pump runs If the grease pressure exceeds 1500 psi this valve will redirect the grease back to ward the reservoir During the lubrication cycle the integrated pressure switch must report to the con trol unit that the required pressure has been attained at least 1029 psi If the con trol unit does not receive this signal it will generate an alarm signal The lubrication cycle ends when the control unit stops the pump The pressure in the primary line then slowly drops to zero via an electrically controlled relieve valve The metering units will then be able to reset themselves and will be ready for the next lubrication cycle after about two minutes System summary EG0102 Single Line General Manual 72 AA y W LA mun q Ff Z i 2 2 AS CNNI o i I W N V g
15. e is achieved because the lubrication takes place while the machinery or vehicle is in operation Every action is automatically carried out by the system The user needs only to refill the reservoir periodically The GROENEVELD Automatic Greasing Systems are designed with great care and thoroughly tested to guarantee a long and fault free life span under the most heavy operational conditions A well functioning system requires e correct assembly e use of the prescribed type of grease or lube oil e aperiodic check of the functionality of the system The periodic check can easily be carried out at the same time as the normal main tenance of the machine or vehicle Moreover because of the careful choice of ma terials the greasing system is nearly maintenance free ATTENTION An automatic greasing system avoids the time consuming manual lubricat ing of important parts Remember however that there can be lubricating points that still have to be lubricated manually Introduction Single Line General Manual Notes 10 Introduction EG0102 Single Line General Manual CONVERSION SIZE AND WEIGHT J Ij LA E i t LAT Qi Y MU J Aw a GROENF VELD Your efficiency is our challenge 11 Conversion size and weight EG0102 Single Line General Manual 2 1 Size and weight conversion 12 Conversion size and weight EG0102 Single Line General Manual 2 2 Tem
16. el Pened s Barcelona SPAIN Tel 34 93 8171822 Fax 34 93 8172061 Groeneveld Transport Efficiency U K Ltd The Greentec Centre Gelders Hall Road Shepshed Loughborough Leicestershire LE12 9NH UNITED KINGDOM Tel 44 1509 600033 Fax 44 1509 602000 Groeneveld Transport Efficiency Inc 1130 Industrial Parkway North Brunswick Ohio 44212 U S A Tel 1 330 2254949 Toll free 1 800 5867283 Fax 1 330 2255213 Mobile 1 800 5867283 Groeneveld Pacific West L L C 1089 Valentine Avenue SE Pacific WA 98047 U S A Tel 1 253 8633700 Fax 41 253 8633131 Mobile 1 253 6061838 Groeneveld USA Brunswick OH 1 330 225 4949 Pacific WA 1 253 863 3700 Groeneveld Canada 1 905 875 1017 Ottawa ON 1 800 263 1760 Edmonton AB 1 800 263 1760 Winnipeg MB 1 800 263 1760 Surrey BC 1 888 326 1971 Atlantic 1 902 883 2234 www groeneveld group com
17. emove the dust cap from the filler connector Carefully clean the filler connector and the connector on the filler hose Secure the filler hose to the filler connector Fill the reservoir to not more than the maximum level 2 cm below the top of the reservoir or until the follower plate meets its stop Replace the dust cap on the filler connector There is a filter within the filler connector in the reservoir If pumping is very difficult the filter could be blocked In this case dismantle and clean the filter Note Keep main pump raised from the bottom of grease pail to ensure no plastic shavings enter the grease system Refilling the reservoir EGO102 Single Line General Manual 72 Ff A LA mun IA GROENF VELD Your efficiency is our challenge EG0102 11 Maintenance JONVNALNIVIA 52 Single Line General Manual Maintenance of Groeneveld s Automatic Greasing System can be combined with normal vehicle or installation maintenance Check the pump paying particular attention to e thelevel of the lubricant top up in time e external damage Check the electronic timer with particular reference to the correct operation of the various functions For this an accelerated test should be carried out see section 6 Check the brake impulse counter and pay attention to the manometer on the pump Operate the brake impulse counter manually by
18. ending on the number of grease points The minimum level 5 cm is marked by a label 3 on the reservoir Follower plate In the standard reservoir a follower plate is placed above the level of the lubricant Figure 9 3 1 This plate follows the level of the lubricant as the level falls the fol lower plate falls with it under the action of a tension spring The follower plate pre vents the increase of air into the lubricant and any consequent soaping of the lubricant Funneling of grease as the level falls is also prevented The follower plate also wipes the reservoir wall clean This allows the level of the lubricant to be checked easily at a glance Other components EG0102 Single Line General Manual 10 REFILLING THE RESERVOIR l ne ee CRY GROENF VELD Your efficiency is our challenge 49 Refilling the reservoir EG0102 50 Single Line General Manual Figure 10 1 Filling the grease reservoir When the lubricant in the reservoir has fallen to the minimum level it must be re filled Generally a filler pump is used for this purpose The procedure Figure 10 1 is as follows With a new filler pump or filling hose the hose should first be primed with lubricant This avoids the pumping of air into the reservoir For this the ball 1 in the snap on connector on the filler hose should be depressed while pumping lubricant through the hose until it is filled with the lubricant R
19. imer produces at set time intervals impulses lasting 3 minutes These impulses energize the solenoid valve in the air supply to start the lubrication cycle With an electrically operated pump the impulses start the pump The interval between successive lubrication cycles is ad justed on the electronic timer If during a cycle the power supply is switched off a complete new lubrication cycle will restart when the power supply is again switched on The electronic timer has a memory in which data is stored even after switching off the power supply The data stored is as follows e interval duration impulse duration conditions for an alarm signal total number of cycles since first fitted total number of alarm signals since first fitted longest series of successive alarm signals in a certain period remaining interval time The data in the memory can be recovered using a special test or read out unit This device should be connected via the socket on the left hand side of the timer 6 2 Adjustment of the cycle time interval The interval time between two successive lubrication cycles can be adjusted using the step switch One of ten time intervals can be selected The standard version has time intervals increasing by 0 5 h steps 0 5 h 1 h 1 5 h etc to 5 h If the power supply is switched off during a cycle the cycle will be ended When the power sup ply is switched on again a complete new cycle will be started 34 Electronic timer E
20. larger as the pump operates for longer periods Principle of operation EG0102 Single Line General Manual SYSTEM SUMMARY Tal C jor GAOENE VELD Your efficiency is our challenge 17 System summary EG0102 Single Line General Manual 4 1 System with pneumatically operated pump and electronic timer PLC pressure switch u L 2 1 solenoid valve G H m 4 ag compressor HE V ignition switch Figure 4 1 System with pneumatically operated pump and electronic timer schematically At a time preset by the electronic timer the circuit to the solenoid valve is closed The solenoid valve opens and allows compressed air from the compressor to flow to the pump The pump piston now rises under compressor pressure and forces grease into the system The lubricant pressure is dependent upon the air pressure on the piston this is the compressor pressure With a compressor pressure of 125 psi and for a pump with 9 1 ratio the grease pressure is 1125 psi The metering units then simultaneously pass a fixed pre selected metered quantity of grease to the points to be lubricated To end the lubrication cycle the electronic timer or PLC opens the electrical circuit closing the solenoid valve Therefore the compressed air supply to the pump is shut off and the piston reverts to atmospheric pressure This allows the piston to return to its starting position and the whole
21. means of the screw Check the entire system and in particular for e damage of tubing e operation of the metering units If a high pressure steam cleaner is used to clean the vehicle or installation the lu brication system pump should be avoided to prevent any possible entry of water through the venting openings Water will not enter under normal operating con ditions REMARK When an automatic greasing system is used time consuming lubricating by hand is largely replaced However do not forget that for example the uni versal joints of the propeller shaft still have to be greased manually Maintenance EGO102 Single Line General Manual 12 FAULT DIAGNOSIS Tal MM y GROENF VELD Your efficiency is our challenge 53 Fault diagnosis EG0102 Single Line General Manual 1 All points to be lubri cated are dry 2 Pump does not work or does not reach working pressure 3 One or more lubrication points are dry while the others receive sufficient grease 4 A lubrication point receives too much grease 5 Pneumatically operated pump Solenoid valve fails to operate or does not operate correctly Fault diagnosis a Pump reservoir is empty b Reservoir filled with grease that is too thick and unsuitable for the system c Main pipe leaking d Electronic timer PLC or pneumatic impulse counter not set correctly If there is another cause please consult your deale
22. ol valve 2 doe Mr p a HKH S Kl VO T DIU WN jema F k 7 Figure 5 3 The electric plunger pump EG0102 Pumps 29 30 Single Line General Manual Pumps The actual pump 5 of the unit consists of six fixed cylinders amid a ring duct The six plungers are driven by the electric motor 9 through a mechanical transmission In the channel between the ring duct and the output port 6 of the pump unit a pressure control valve 14 and an electrically operated return valve 10 have been incorporated The pressure control valve is used to maintain a constant grease pres sure during the pump cycle The return valve allows the grease pressure in the sys tem to fade after the pump cycle has ended The standard electric plunger pump is fitted with a pressure switch 8 which is used to check that the required grease pressure is attained during the pump cycle The optional low level switch 4 in the reservoir will cause the control unit to generate an alarm signal when the level of the lubricant in the reservoir becomes too low and needs to be replenished The pump is electrically onnected with the control unit through a connector 7 The reservoir 2 is mounted on top of the pump unit The reservoir is filled via the filler port 11 at the side of the pump unit A filter 13 prevents contaminations from entering the reservoir Any bubbles of air that might be introduced in the lu bricant while filling the
23. ontrol unit does not receive this signal it will generate an alarm signal EG0102 Pumps 32 Single Line General Manual Pumps Oil pumps at extreme circumstances please consult your local GROENEVELD organization 20 24 Ibs 22 44 Ibs EG0102 Single Line General Manual Hi LA mun M HN Ff CoS as D li Was OA 73 TZ 9 JIMILL SINOYLI 13 sl b lt GAOENE VELD Your efficiency is our challenge EG0102 Electronic timer 33 Single Line General Manual 6 1 Electronic timer TIJDSCHAKELAAR AUTOMATISCH VETSMEERSYSTEEM STEUERGERAT AUTOMATISCHE FETT SCHMIERANLAGE GROENEVELD TEMPORISATEUR SYSTEME DE GRAISSAGE AUTOMATIQUE Groeneveld Transport Efficiency B V PO Box 777 4200 AT Gorinchem The Netherlands Tel 31 183 64 14 00 fax 31 183 62 34 05 TIMER AUTOMATIC GREASING SYSTEM greasing interval hours smeerinterval uur 10 11 12 789 Schmierintervall Stunden i SEE intervalle sr 2 heures E 2 3 4 E E 4 5 essai test A test B connection test unit connector uitlees unit connection d unit d ism S D O o e i C S a o wn f a 2 lt lt type 099 01 12 VDC Figure 6 1 Electronic timer The greasing system with a pneumatically operated or electrically operated pump can be controlled by an electronic timer Figure 6 1 The t
24. perature conversions EG0102 Conversion size and weight 13 Single Line General Manual Notes 14 Conversion size and weight EGO102 Single Line General Manual PRINCIPLE OF OPERATION GROENF VELD Your efficiency is our challenge 15 Principle of operation EG0102 16 Single Line General Manual Each system consists of a pump with an integral reservoir a control unit a main pipe one or more metering unit blocks metering units secondary piping and con nectors Lubricant is transferred from the reservoir by the pump via the main pipe to the metering unit blocks Each metering unit is connected by a secondary pipe to a lubrication point An elec tronic timer PLC or a pneumatically operated impulse counter depending on whether there is a continuous electrical supply available is used to determine when lubrication occurs Generally only trailers and semi trailers are equipped with a pneumatic brake im pulse counter since they usually do not have a continuous electrical supply There are two main types of pumps electrically operated pumps with electronic timer or PLC pneumatically operated pumps with electronic timer PLC or pneumatic impulse counter The electrically operated pump is used mainly for installations or vehicles without a compressed air supply The electrically operated pump is also used for installa tions where a large lubricant delivery is required The delivery is
25. pneumatically operat ed pump usually fitted to the pump is a normally closed free venting type The valve is connected electrically by an M24 screw connector 9 1 1 Technical data open venting open eens 46 Other components EG0102 Single Line General Manual 9 2 Pressure switch Figure9 2 Pressure switch A pressure switch is included in the lubrication system in the main pipe to provide an alarm for too low a pressure in the system during the lubrication cycle This switch closes at a pressure of 600 psi making a connection to earth If this does not happen during the lubrication cycle because insufficient or no grease pressure is generated an alarm will be given During the remaining cycle time there will be an intermittent alarm signal This alarm will be repeated after a preset time if the problem is not corrected An M24 screw connector connects the switch electrically For a system with a pneumatically operated pump the pressure switch is fitted to a distribution block The electrically operated pump is provided with a built in pres sure switch 9 2 1 Technical data EG0102 Other components 47 48 Single Line General Manual 9 3 9 4 Reservoir Figure 9 3 Pump The reservoir 2 is made from impact resistant plastic that can withstand the influ ences of fluctuating temperatures The reservoir can hold a quantity of lubricant that in most cases is sufficient for about 4 months dep
26. r a Pneumatically operated pump No or too low air pressure b Piston does not rise If there is another cause please consult your dealer a Break in the secondary tubing b Inoperative metering unit a Internal leak in the metering unit a Bad or open electrical connections b Solenoid valve internally fouled with water and or rust from the vehicle air sys tem a Fill the reservoir see sec tion 10 b Remove and clean the reservoir Refit and fill the reservoir with the correct grease Remove the end plugs from the distribution blocks and pump the old grease out of the system c Repair the line and bleed the system if a new piece of piping has been fitted d Reset the electronic timer PLC or brake impulse counter a Ensure there is an air pressure of 90 to 125 psi b Dismantle the cover of the pump casing and clean the piston a Repair or replace the line b Remove the metering unit and fit a new unit a Remove and clean the metering unit or fit a new unit a Check the electrical cir cuit and connections to the solenoid valve Check the valve with direct current bypassing the electronic timer Watch out for short circuits b Dismantle clean and refit the valve or fit a new valve Clean the vehicle air system EG0102 Single Line General Manual 6 Continuous buzzing from a Short circuit a Check wiring and test the electronic timer solenoid
27. ronic timer or PLC will sound an alarm signal A level indicator switch 2 not in all versions provides an alarm signal if the lubricant in the reservoir falls be low a certain minimum level On the right hand side between the connector for the primary line 6 and the con nector fitting 4 there is a right angle connector for air venting and overflow 5 When filling the reservoir with lubricant the air above the follower plate escapes This air flows downward through an opening in the piston line and leaves the pump via the right angle connector 5 The escape of a small quantity of lubricant via this connector during venting is quite normal A version with the connections for the primary line and for the connector on the left hand side of the pump can also be supplied if required 5 2 2 Technical data Gear pump deliver 120 cc minute 120 cc minute d NLGI 0 grease at 20 C NLGI 0 grease at 20 C 855 ps 855 psi temperature range 4 F to 158 F 4 F to 158 F NLGI 0 grease NLGI 0 grease at extreme circumstances please consult your local GROENEVELD organization 28 Pumps EG0102 Single Line General Manual 5 3 Electric axial plunger pump 5 3 1 Pump unit follower piston reservoir guide rod of follower level switch plunger pump coupling for primary grease line electric connector pressure switch electric motor 10 return valve 11 filler port 12 overflow port 13 filter 14 pressure contr
28. rs H lsdonk DEUTSCHLAND Tel 49 2841 793520 Fax 49 2841 7935222 Groeneveld France 53 rue Antoine Condorcet 38090 Vaulx Milieu FRANCE Tel 33 4 74999333 Fax 33 4 74999350 Groeneveld France IT 53 rue Antoine Condorcet 38090 Vaulx Milieu FRANCE Tel 33 4 74999333 Fax 33 4 74999350 GINTEC Active Safety Ltd 49 Hasharoshet 1st Karmiel 20101 ISRAEL Tel 972 4 9882220 Fax 4972 4 9883179 Groeneveld L Efficienza nel Trasporto S r l GENT Via Chiari 100 23868 Valmadrera Lecco ITALIA Tel 39 3 41200536 Fax 39 3 41201539 Groeneveld Italia GRIT Via Chiari 100 23868 Valmadrera Lecco ITALIA Tel 39 3 41201133 Fax 39 3 41201158 Groeneveld Transport Efficiency B V Postbus 777 4200 AT Gorinchem THE NETHERLANDS Tel 31 183 641400 Fax 31 183 624993 Groeneveld Information Technology B V Stephensonweg 12 4207 HB Gorinchem THE NETHERLANDS Tel 31 183 641400 Fax 31 183 641690 Groeneveld New Zealand Ltd 58 Newton Road P O Box 4509 Mt Maunganui NEW ZEALAND Tel 64 7 5720684 Fax 64 7 5724587 Groeneveld Polska Sp Z o o Ul Ostrowska 476 61 342 Poznan POLAND Tel 48 61 8726207 08 09 Fax 48 61 8798166 Groeneveld South Africa Unit 65 Sunny Rock Park Sun Rock Close Germiston 1401 SOUTH AFRICA Tel 27 11 4503977 Fax 27 11 4503980 Groeneveld Ib rica S A Pol Ind Mercederias C Font de Sant Llorenc 36 08720 Vilafranca d
29. ssure bypass valve keeps the system at a preset pressure during the pumping cycle To end the lubrication cycle the electronic timer or PLC opens the electrical circuit the gear pump then stops Pressure in the output main primary pipe to the meter ing units then falls by means of a built in pressure discharge valve The metering units then automatically refill themselves after which they are ready for the next lubrication cycle System summary 21 22 Single Line General Manual 4 4 System with electric plunger pump primary grease line secondary grease line control unit power supply Figure 4 5 System with electric plunger pump schematically GROENEVELD Automatic Greasing Systems with electrically driven pumps are usu ally employed on vehicles or machines on which electric power is always available An electric pump is also the best choice if the lubricant demand of the system is high The control unit an advanced electronic timer for instance holds a number of system control variables such as the lubrication interval and the duration of the lu brication cycle The control unit is able to process and store all functional errors that may occur and automatically maintains an electronic log book If the greasing sys tem requires action the controller will generate an alarm signal i e if the reservoir needs to be refilled At a given point in time the control unit will start the pump and lubric
30. t p ra cuv Mu Me GROENEVELD Your efficiency is our challenge EG0102 Pumps Single Line General Manual 5 1 Pneumatically operated piston pump 5 1 1 Pump unit reservoir with follower plate air venting channel grease channel return channel to reservoir main line connection pressure channel return valve non return valve grease pressure colour indicator 10 compressed air connection 11 main air piston 12 spring 13 filler connector 14 small grease piston 15 grease chamber 16 flapper valve 17 connection to reservoir 09 10 4945 wo IS gt 7 AK 4 w ETK l To x M A q i Figure 5 1 Pneumatically operated pump 24 Pumps EG0102 Single Line General Manual If pressure is applied via the compressed air connection 10 the main piston 11 will be forced upwards applying pressure to the lubricant in chamber 15 The pres sure in chamber 15 forces valve 16 against the seat The connection 17 to the reservoir 1 is thus closed The lubricant leaves the chamber 15 via a channel 3 through the non return valve 8 into the main or primary line The metering units are brought under full pump pressure passing their metered quantities of lubricant into the lubrication points As a result of the pressure differential at the return valve 7 the return channel 4 remains closed At the end of the complete lubrication cycle the air pressure under
31. the distance between the striker and the adjustment bolt can be measured Technical data cycle time minimum 2 brake impulses minimum 2 brake impulses cycle intervals 10 80 brake impulses 10 80 brake impulses Pneumatic impulse counter 39 Single Line General Manual Notes 40 Pneumatic impulse counter EG0102 Single Line General Manual Hi M mun A Cass SLINN DNI LEAIAI 7 i Iz E Li C 9 pi KC uas D v lt GAOENE VELD Your efficiency is our challenge EG0102 Metering units Single Line General Manual Figure 8 1 Distribution block with metering units There are 11 metering unit types 1 available for the Single Line system each with a differing metered lubricant quantity By careful selection of the type of metering unit each lubrication point can be provided with the right quantity of lubricant The metering units are fitted in groups on distribution blocks 2 this is a cast brass distribution block to which the primary main line 3 is connected The blocks are available with several ports or outlets to which metering units can be connected The unused outlets should be blanked off The metering units are also made of brass and are because of their enclosed de sign exceptionally suitable for use in dirty and dusty conditions It is not advisable to open the metering units as this allows the entry of dirt and
32. the grease point This stroke length hence the capacity of chamber 3 is determined by the number and thick ness of the spacers Figure 8 3 1 Metering units 43 Single Line General Manual 8 4 Phase B KA i MAA ANNE guum Ses pe Figure 8 5 Metering unit in phase B When the pump stops and as the grease pressure drops spring 7 Figure 8 5 will push plunger 4 back to the left closing off channel 1 O ring 9 prevents grease from being sucked back from chamber 6 Plunger 5 is pushed back by spring 10 and presses the grease in chamber 3 via channel 2 to chamber 8 8 5 Phase C Figure 8 6 Metering unit in phase C During the next lubrication cycle the same happens as in phase A Chamber 8 Fig ure 8 6 however is now filled with grease As plunger 4 moves right under influ ence of the grease pressure the grease in chamber 8 is pressed via chamber 6 and the secondary grease line to the grease point During all this O ring 9 is pressed outward to allow the grease to leave chamber 8 44 Metering units EG0102 Single Line General Manual OTHER COMPONENTS qu NUT q YC CC A i t Wu Of Y WW MWC J GAOENE VELD vour efficiency is our challenge 45 Other components EG0102 Single Line General Manual 9 1 Solenoid valve Figure 9 1 Solenoid valve The solenoid valve Figure 9 1 between the air tank and the
33. the main piston 11 falls allowing the piston to be pushed downward by the spring 12 At the same time flapper valve 16 is released and because of the reduced pressure in the chamber 15 lubricant is drawn from the reservoir The non return valve 8 prevents grease from the system piping and metering units from flowing back into the chamber 15 The pressure in the main pipe opens the return valve 7 via the channel 6 This allows the pressure of the lubricant to flow via the channel 4 to the reservoir The metering units with this pressure drop can now automatically refill themselves fol lowing which they are ready for the next lubrication cycle A manometer can be connected to the lubricant channel showing the pressure in the main line It is also possible to replace this manometer by a pressure colour indi cator 9 At the start of the lubrication cycle this will be red as a result of the air pressure and will change to green at the end of the cycle due to the pressure Green thus indicates that the pump has worked and that sufficient pressure has built up in the grease line system If the color remains red this means that insuffi cient pressure has built up in the system This could be caused by leakage from the main line EGO102 Pumps Single Line General Manual 5 1 2 Technical data Grease pumps delivery 42 cc stroke temperature range 13 F to 176 F NLGI 0 grease 13 86 lbs 14 85Ibs 153415
34. thus is a potential cause of faults 8 1 Types of metering units The delivery per lubrication cycle of a metering unit is determined by the number and thickness of the spacers mounted between the head and the housing of the metering unit Figure 8 2 The following metering units are available Nr 0 Nr 1 Nr 2 Nr 3 Nr 5 Nr 6 Nr 8 Nr 85 Nr 9 0 025cc 0 05cc 0 1cc 0 15cc 0 25cc 0 3cc 0 4cc 0 7cc 1 0cc Figure 8 2 Types of metering units 42 Metering units EG0102 Single Line General Manual 8 2 8 3 EG0102 Operating principle Xu r pa Y sl AAA Kg r AM Figure8 3 Metering unit in initial position Figure 8 3 illustrates a new metering unit one that has not yet been filled with grease Item 1 in this figure is the spacer which determines the delivery of the me tering unit see previous paragraph The metering units that are used in your greasing system may differ externally or even internally from the one illustrated here However the operating principle is always the same Phase A 4 3 5 gS ee p Exe NEEDS ANU Ns MID ji Figure 8 4 Metering unit in phase A The pump presses the grease into grease channel 1 The grease pushes plunger 4 past channel 2 The grease now fills chamber 3 and pushes plunger 5 to the right The stroke length of plunger 5 will determine the amount of grease that will be pressed through the secondary grease line to
35. ton a normal lubrication cycle will then follow The switch can be set in any position except test A or test B After this test the electronic timer will work at the interval set The test B position is only for use with the test or read out unit Alarm signals Alarm signals can be generated by the electronic timer in various circumstances The standard version uses a built in buzzer In other versions another external alarm indicator can be fitted for example a lamp The alarm signal is generated in the following situations e After reaching 70 of the cycle time 70 of 3 minutes 2 minutes the pressure switch should have connected to earth If this is not the case because insufficient pressure has been built up then a continuous alarm signal is generated e f a level indicator switch is fitted to an electrically operated pump an intermittent alarm is generated when the level of the lubricant in the reservoir falls below a set minimum This signal will be generated throughout the entire cycle If moreover insufficient pressure is built up the pressure alarm will take over after 2 minutes causing a change in the frequency of the alarm signal e The electronic timer runs a self test after the power supply is switched on if there is a fault condition an intermittent alarm is generated This can occur if no interval is selected by the step switch Electronic timer 35 Single Line General Manual If the
36. vehicles and machinery In addition to the Automatic Greasing System GROENEVELD also delivers products such as e speed limiters on board computer systems automatic oil level controllers reversing protection systems temperature recording systems GROENEVELD delivers a complete program of cost saving and comfort enhancing products Figure 1 1 GROENEVELD Head office 1 2 GROENEVELD Greasing Systems GROENEVELD Automatic Greasing Systems ensure the daily maintenance of every thing that has moving parts They avoid unnecessary machinery wear and down time and thus save cost and prevent exasperation Introduction EG0102 Single Line General Manual 1 3 EG0102 GROENEVELD greasing systems are used by for example production companies machinery used in service industries agriculture ships the offshore industry and the transport industry In the following list are the most important advantages e increase of the service intervals thus less unnecessary down time less wear of the lubricated parts because of accurate and constant lubricating reduced repair and replacement costs reduced unexpected down time fewer production losses Single Line Automatic Greasing Systems With a Single Line Automatic Greasing System all lubrication points of a vehicle or machine are automatically lubricated at the correct time with the correct dose Moreover optimum grease or lube oil distribution over the whole lubricating sur fac
Download Pdf Manuals
Related Search