USER MANUAL
Contents
1. rime Mode SD Memory Card E H T nn STEP 6 2 BH et tir M lode SD SD Memory Card Change mode from PLIN to PROG STEP 6 4 Now Booting up Heading SU Memory Gard Bett ine Mode 5 7 EE Card Really Download STEP 6 3 fer st E Mo Ir SD Memory Ca nd Impossible to wnte PUE file Mo area for PCE file STEP 6 5 17 18 STEP 6 6 STEP6 7 1 Mod Ha SD E S S Card Lih a mode trem FELIS to ALA due V STEP 6 8 Maria Pato i STEP 8 2 Msetting Mode Leo MSettins Mode E 507 ne Carda 52 Memory Card ot Tle LAA Cop STEP 8 3 STEP 8 4 Wetting M de FROM Clearing STEP 8 5 Memory Card STEP 8 6 Menu Ai r bermal Now Booting up Heading SD Memory Gard STEP 9 3 INITIAL LOAD STEP 9 5 STEP 9 2 STEP 9 4 STEP 10 19 iagram d iring W LED1 ON GREASE LEVEL OK MAIN RELAY 24 12 VOLTS OPERATOR INTERFACE ATO SAMPS PUMP MOTOR ATO 3AMPS 9 NOTE 1 HARNESS 3 OF THE MAIN_POWER AT LAST oR N B 1 Pump unit selection 12Volts or 24Volts must match the power source SPARE ww zc 2 For 12Volts source 12Volts 24Volts converter SYS303 must be used connected in series 240 ECU AND JUNCTION BOX2. All new Envirosys parts are warranted for a period of three 3 months from the date of delivery Note Contamination and non Envirosys greases usage will void the system warranty Model number Unit serial number Operator interface serial number Date manufactured Date purchased Technical Support Division Envirosys div of S T L Lubrifiants 208 Du Parc Industriel St Prime Qu bec Canada G8J 281 Phone 1 418 251 1218 Fax 1 418 251 1364 info envirosysforest com www envirosysforest com CONTACT YOUR DEALER FOR MORE INFORMATION 10 APPENDIX DECLARATION OF INCORPORATION According to directive 2006 42 EG Annex 2B S T L Lubrifiants 208 Rue de Parc Industriel St Prime Qu bec Canada G8J 2B1 Declare under our sole responsibility that the products Grease lubrication equipment for saw chain cutting attachments Envirosys 12 VDC or 24 VDC from year of manufacture 2010 and onwards following the provisions of Directives 2006 42 EC Machinery 2004 104 EC Electromagnetic compatibility EMC to which this declaration relates is in conformity with the following standard s or other normative document s EN ISO 12100 1 A1 2009 2 A1 2009 EN 60204 1 2006 EN 61000 6 2 EN 55011 EN 61000 6 4 The partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of Directive 2006 42 EC O4 O
3. HARNESS LEGENDS PRESS ONCE PUMP RN INE EEE EEE PRESS AGAIN PUMP OFF 22 5FT 4 OPERATOR INTERFACE PUMP RELAY 3 4 5 6 7 8 9 18 2SJOOW OUTPUT SPARE VALVE PUMP UNIT 24 VOLTS OR 12VOLTS M CROUSSETTE 2140 17 ST I 208 RUE DU PARC INDUSTRIEL ST PRIME QUE GB 251 ELECTRICAL SCHEMATIC ENVIROSYSe3 OR S ENVIROSYSeVER 3 ENVIROSYSeVER 3 mm jem 0100 3AWA Javas ZUM 20 Hydraulic diagram QUI oessm M CROUSSETTE 2014 06 16 VERIFIE VERIFIE APPROUVE S LUBRIFIANTS 208 RUE DU PARC INDUSTRIEL ST PRIME QUE G8J 2B1 TEL 418 251 1218 SCHEMA HYDRAULIQUE POMPE ENVIROSYS ees ku l 21 22 ENVIROSYS PARTS LIST 23 24 25 26 4 F SS A 4 un BA Ww DOODO 44 IA e P N Electronic Control Unit Diagram PUMP MANUAL OVERRIDE LED1 ON PRESS ONCE PUMP ON GREASE LEVEL OK PRESS AGAIN PUMP OFF FUSE2 VALVE ATO 3 AMPS LED2 ON FUSE2 OK LED3 ON FUSE3 OK m hel gt I m a FUSE3 PUMP MOTOR ATO 3 AMPS 28 PARTS LIST TE s TT MORGEN TT sm o TT TT TT a TT To sm aa TT Tu Ta TT Te s Tu lT no TT TT ew 3 30 35057 CROSS ADAPTER S YS039 STRAINER 29 PARTS LIST He PRE
4. USER MANUAL Installation and 5 Instructions E my l o Sy Sy Automatic Bar amp Chain Grease System for Logging Equipment Increase Productivity Reduce Operating Costs Complete Elimination of Chain Oils SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE STL LUBRIFIANTS D The maker of Envirosys Version 6 June 2014 TABLE OF CONTENTS 1 INTRODUCTION na nn att eee ot 1 2 SAFETY 2 3 GENERAL DESCRIPTION nnne ayayayay ke 2 SPECIFICATIONS uuu ki a Waaa ee kal eae 3 5 INSTALLATION uu uu Z ua ce baa ag 4 6 GETTING STARTED uuu u isk uu nennen 5 7 OPERATING u au rrr e an A 6 8 MAINTENANCE u u 8 9 5 9 10 WARRANTY risti ESRA tato 10 IE APRENDO mE 11 a Declaration 12 b Grease Technical Data u ee eee 13 c Updating the Envirosys Software eke eke keke NANTANG 15 d Wiring Diagram ee 20 e Hydraulic Diagramm ee 21 r Parte iu uuruuu acticin t m 22 g Electronic Control Unit nnne 28 INTRODUCTION CONGRATULATIONS You have just invested in the next generation of lubricating technology for your logging equipment You
5. channel on the saw unit 6 You are now ready to do what you are doing best harvesting NOTE The Envirosys system comes with factory setting grease injection parameters All parameters can be modified by the operator at any given time Please refer to the OPERATING Programming section of this user manual for more detail OPERATING Filling the system with grease Unscrew the reservoir lid Take a 2kg grease accordion cartridge and connect it to the top of the reservoir 3 Press it down to empty the cartridge A Put the reservoir lid back in place E hl N M Clean prior to refill amp do not overfill Safety advice We recommend the use of protective gloves amp glasses when refilling Note Always clean the area around the lid before open to prevent debris from falling into the tank when filling the system Programming the Operator interface Home Page The version of your software appears here Saw selection screen Press SEC SAW 1 2 and AUX grease injection settings Injection duration screen Press the desired time button SEC SAW 1 2 or AUX Select new duration time in seconds Press the left arrow to confirm and return to the previous screen Press the right arrow to access the pre charge injection screen NOTE The injection duration period may vary according to operation conditions type and size of wood and chain saw types 404 vs 4
6. pitch Pre charge injection screen Adjust the time for which the saw can stay inactive without pre charge Adjust the pre charge duration time in seconds Adjust the start up pre charge duration time in seconds Press twice the left arrow to return to the main screen NOTE The pre charge functions are used to ensure non interruptible supply of grease to the saw chain unit following grease pressure drop due to idling period of operation Factory settings gt 1 75 seconds for the injection duration time gt 30 seconds delay prior to pre charge gt 2 seconds pre charge following delay Y 20 seconds pre charge on initial start up Numeric keypad screen Use this numeric keypad to change settings Press the arrow button to return to the previous screen Grease Low Level Alarm screen Indicates a system fault due to a low level of grease Note Adding grease will reactivate the system and this message will disappear Please refer to the Updating the Envirosys Software section in Appendix when necessary MAINTENANCE Performing routine actions to keep the Envirosys system in working order or prevent trouble from arising is part of a good preventive maintenance plan that will keep your Envirosys system reliable and performant for many years Cleaning the Envirosys system Always clean the top of the reservoir before filling Avoid dirt contamination when manipulating grease cartridges Clean the air ve
7. SSURE ABAD oso TT CHEKVAMESORT os O TT sosa TT mos 2 ose ApAPTER FOR SLEEVE sme s 6 30
8. ction duration time period settings Insufficient pre charge injection Increase the pre charge injection duration duration time settings time period Conduit or hoses disconnected or Reconnect conduit and or hoses leaking Identify and fix the leak Defective piston Use manometer to measure pump pressure Should read 300 bar 4300 psig Replace defective piston Relief valve settings too low Adjust relief valve with a grease manometer to 300 bar 4300 psig Contamination Verify for contaminants and clean the system Air entered the system Eject it by disconnecting the connector and bleed the line until grease comes out FROZEN GREASE Improper grade selection winter vs Verify for grease hardiness and change grade summer PUMP RUNNING The manual override button on the Push the manual override button once CONTINUOUSLY electronic control unit is ON WARRANTY All Envirosys system components are guaranteed for a two year 2 period only if the following rules are applicable s System cleanliness lf solid contaminants are found inside the system no warranty can be applied e Mixing other products different from Envirosys greases Since the system has been tested and validated with our Envirosys greases any use of other products voids the warranty s Any misuse of the system is not covered by the warranty fthe system is returned to the purchase location for repair no labour costs will be charged
9. ctober 2010 Robert Soucy chemist President S T L Lubrifiants St Prime Quebec Canada G8J 2B1 Phone 418 251 1218 Fax 418 251 1364 12 aim Envir GREASE DATA BIO LUBRICANTS BIO lubricants are a family of biodegradable and non toxic fluids They were especially formulated to offer optimal performance for any lubricating application i e hydraulic systems industrial gears slide ways pneumatic and percussion tools These lubricants are manufactured with biodegradable vegetable oils and provide optimal protection for forestry equipment s sawmills slide ways pneumatic tools and jack drills The additive package used is ash less and approved for incidental contact with food H 1 and H 2 These lubricants do not affect yellow metals moreover they offer superb performance under the most adverse operating conditions All BIO lubricants from S T L LUBRIFIANTS offer the following characteristics Superior load carrying capacity and resistance to abrasion Superior protection against rust and corrosion Outstanding anti wear properties and Higher resistance to oxidation than most conventional biodegradable lubricants In addition these lubricants form a highly adherent and tenacious film which increases metal surface protection while reducing stray mist P Q CHARACTERISTICS BIO fluids possess the following characteristics e Virtually no toxic
10. d This pressure reducing valve is available in the ENVIROSYS system parts list Installing the Electrical Cables 1 Connect the pump unit 5 and 6 to the electronic control unit 8 using the pre assembled cable 2 Connect the operator interface to the electronic control unit using the pre assembled cable 1 3 Identify and connect the saw signal positive or negative to the control unit 3 If no signal is available in the cabin the signal will have to be brought from the saw unit located the head It is recommended that the signal be identified by the manufacturer A Connect the electronic control unit to the main power source Key Relay 2 IMPORTANT NOTE Your Envirosys system must be ordered adequately to match your available electrical system i e 12 VDC OR 24 VDC Note that a 12 to 24 VDC converter unit is available upon request The attached wiring diagram in appendix can also be used in support to installation GETTING STARTED 1 Start by manually filling the supply hose with Envirosys grease Use a manual grease pump not the Envirosys system for now 2 Fill up the reservoir by adding two Envirosys 2kg chain grease accordion cartridges 3 Power up the Envirosys system by turning ON your equipment start key s The right operation of the Envirosys system will be confirmed when the operator interface turn ON 4 Press the Initial Load button 5 Verify that grease is coming out of the lubrication
11. e the potential for environmental contamination is a concern s Envirosys BIO EP GREASE continues to lubricate in the presence of water s Envirosys BIO EP GREASE has an exceptional low coefficient of friction s Envirosys BIO EP GREASE has a very high dropping point gt 343 C gt 644 F ENVIROSYS ALC GREASE Envirosys ALC winter amp summer grades are premium quality extreme pressure multi purpose greases and heavy duty applications that have a smooth and tacky consistency and is amber in color up to 3252F in plain anti friction bearings slides and way with frequent resupply Special extreme pressure additives provide a high load carrying capacity and anti wear protection Excellent water resistance provides bearing protection when water wash out or leaching conditions are encountered Excellent dispensability and pumpability properties make this grease suitable for various methods of dispensing including centralized lubrication systems Applications and Recommendations Excellent shear or mechanical stability excellent oil retention and good thermal stability make this grease a prime choice in such applications as plain and anti friction bearings especially where high temperatures occur roller and needle bearings flexible couplings automotive disc brakes water pumps fan bearings electric motors slides and ways where excellent adhesiveness is required Envirosys ALC greases deliver almost as much advantages as o
12. en using your ENVIROSYS system s Never modify the ENVIROSYS system in any way e Never use other grease than the ones recommended by the manufacturer s Inspect the pump control unit pipes and cables as recommended Other safety guidelines s Always use the necessary personal protective equipment Install the ENVIROSYS system in a place where re filling the reservoir with grease can be done without risk of slipping and or falling down s Clean the ENVIROSYS system as needed GENERAL DESCRIPTION The patented ENVIROSYS system is replacing oil used to lubricate the cutting parts of a harvester head with biodegradable or standard chain grease Through an ingenious system using an operator interface in the operator cabin the chain grease is injected under pressure reaching and protecting the cutting parts up to six times more effectively than with a conventional oil system The ENVIROSYS system consists of an electric pump a reservoir capable of storing two special chain grease cartridges of 2 kg approximately 4 4 lbs each an operator interface and electrical cables Grease Grease Pump ra Reservoir Operator aka b w Interface 4 Chain Grease 1 Cartridge va Electronic Control Unit TX i Electrical e wc gt cables 12 VDC to 24 VDC converter SPECIFICATIONS Weight empty Dimensions Height x Diameter Operating temperature 22 F to 175 F Po
13. ity s Biodegradability higher than 97 96 s Exceptional anticorrosion antirust extreme pressure and anti wear properties a Excellent oxidation stability and high adherence to surfaces s Good low temperature properties s Excellent anti foam properties These will be approved by organizations such as NSF and CFIA Other viscosity grades will also be available in a near future Clearly these lubricants are ideal for industries to which the environment and the welfare of employees are a concern ENVIROSYS BIO EP GREASE Envirosys BIO EP GREASE winter amp summer grades are high temperature multi purpose greases with low coefficient of friction Envirosys BIO EP GREASE is ideal for applications where there is constant environmental exposure due to pass through lubrication unsealed bearings or similar open design 13 Envirosys BIO EP GREASE is an industrial grease that is not just rapidly biodegradable and operator safe but environmentally safe Envirosys BIO EP GREASE is made from a vegetable oil carrier The risk of both water and soil contaminants is reduced and risk of long and short term liability is minimized Use Envirosys BIO EP GREASE where grease is entering the environment ADVANTAGES s Envirosys BIO EP GREASE contains no petroleum oil carriers petroleum based additive packages or metal additives such as lead or zinc s Envirosys BIO EP GREASE can be used in centralized dispensing system applications wher
14. nd Converter All pre wired and numbered cables for easy installation 12to24 VDC converter available upon request included with 12 VDC system INSTALLATION The ENVIROSYS system can be installed on all models types and brands of harvester head and forestry machinery The device is completely independent from the existing hydraulic systems and can be removed and re installed if the machinery is upgraded Unpacking We package your ENVIROSYS system with the greatest care so that it ships safely Under certain circumstances however damage can still occur during transit and handling When you receive your ENVIROSYS system unpack it carefully inspecting it and all parts for damage Also ensure that all parts are included If any parts are damaged or missing please contact your dealer immediately WARNING Before installing the ENVIROSYS system always TURN OFF main power to system Installing the Pump Reservoir and Electronic control unit 1 Find a protected area with easy access e g engine compartment which provide good protection and warmer environment during cold weather Leave enough space above and around the reservoir to allow refilling Drill two holes of 10mm 3 8 horizontally center to center distance 120 mm or 434 Secure the pump and reservoir with supplied bolts on a solid surface Secure the electronic control unit nearby the pump and reservoir less than 1m 3 feet WN Installing the Operat
15. nt passage underneath the black lid on top of the reservoir to allow free flow of grease DO NOT mix other lubricant or products with Envirosys greases Note Contamination and non Envirosys greases usage will void the system warranty Replacing a piston s Remove the bottom part of the pump Make sure the eccentric shaft is not facing the piston to ease its insertion the vertical scraper inside the reservoir must face the piston that will be removed Use the manual override button located on top of the electronic control unit to position the excentric shaft s Replace the piston manually in order to avoid damaging threads s Check for any leak after the installation Recommended spare parts s Pistons s Check and relief valves s Pressure reducing valve for some harvester head models Pipes and fittings s Springs s Fuses TROUBLESHOOTING Virtually all harvester operators experience basic common problems at one time or another while operating With the Envirosys system most of them are correctable and generally require only a minor adjustment of the installation or operation technique It is important to be aware of the possible causes of problem in order to take the appropriate actions PROBLEM POSSIBLE CAUSE SOLUTIONS NO GREASE BEING Power off Turn power ON to the Envirosys system INJECTED Verify Verify and change fuses Verify and change fuses fuses Insufficient injection duration time Increase the inje
16. or interface 1 Find an appropriate space in the operator cabin 2 Ensure reachable access for the operator to control the various injection parameters during operation 3 Usethe bracket provided to support the touch pad display A Screw the operator interface in place CAUTION Try to stay away from electromagnetic interference EMI e g Radio FM Installing the Grease Conduits Not provided 1 Use existing oil conduit or hose if any by simply connecting it to the pump outlet 2 Inthe absence of oil conduit use 14 diameter hydraulic quality hose approx 6 35 mm equivalent to SAE 100 R2AT DIN EN 853 2SN 400 bar 5800 psi 3 Install the conduit along the hydraulic lines on the boom of the harvester machine from the main unit to the saw bar The feeding line installation should take into consideration boom configurations i e telescopic or extendable masts 4 Connect the conduit to the pump unit and to the saw bar using JIC female swivel 04 type fittings whenever possible NOTE A larger hose diameter does not provide any advantages or disadvantages Each 10 metres 33 feet length of 14 diameter hose section corresponds to a volume of 1300 cc or approximately 1 3kg of grease Some harvester head models Supercut specify a maximum 50 bar pressure in order to avoid gasket damage In these cases a pressure reducing valve has to be installed from 300 to 50 bars near the saw block to avoid exceeding the prescribed standar
17. r purchase ensures years of clean reliable and highly cost effective operations We trust that you will appreciate the quality of our ENVIROSYS Automatic Bar amp Chain Grease System Please read this manual in its entirety Its purpose is to familiarize you with your ENVIROSYS system safe installation proper operation and maintenance It contains information that is useful to you now and in the years to come So keep it handy and refer to it as needed The performance of your ENVIROSYS system depends of many variables Since all installations are unique the general information and operating procedures presented here can only serve as useful guidelines rather than hard and fast rules Should you have any questions do not hesitate to contact your dealer for additional information The ENVIROSYS Automatic Bar amp Chain Grease System is manufactured and warranted STL Lubrifiants 208 rue du Parc Industriel St Prime Quebec G8J 1 LUBRIFIANTS Phone 1 418 251 1218 Fax 1 418 251 1364 Th e ma ker O f En viro SYS info envirosysforest com www envirosysforest com SAFETY INFORMATION Read and understand this User s Manual thoroughly before installing and using the ENVIROSYS Automatic Bar amp Chain Grease System Make sure to install the ENVIROSYS system s According to the manufacturer s recommendations s n accordance with all applicable codes employing qualified technician Wh
18. ur Envirosys Bio version for the environment since the volume of lubricant consumed is reduced drastically compared to the old method of using chain oils 14 UPDATING THE ENVIROSYS SOFTWARE Step 1 Take off the left side panel star screwdriver Step 2 Simply slide the face cover to the left on display Step 3 Put the power on Step 4 Insert the SD card into the slot and push it down until you hear a clic Step 5 Go to the page setting mode Step 6 Installing the new program Select SD PLC you should see the program on the SD card FP V9 1 Press download and then OK to confirm that you really want to overwrite the current program Next Change mode from RUN to PROG sure Press OK Impossible to write PCE file no area for PCE file Press OK Completed Press OK Change mode from PROG to RUN Sure Press OK Step 7 Back on the screen setting mode Step 8 Chose SD gt GT you ll see GT V 9 1 press on thas and confirm that you want to copy this really download OK Copied 100 Press OK Step 9 Press ESC to come back to the main screen Step 10 Remove the SD card and close everything in the reverse order it has been dismanteled 15 16 2 0 8 STL J yop MODEL DPERATOR INTERFACE SERIAL 13012170 STL DATE 2014 04 22 VOLTS ARPS nm M STEP 1 3 F TA STEP 4 2 Memory Card Menu Manual Automati 5 2
19. wer maximum 50 Watts Reservoir capacity Approx 5 kg Approx 11 Ibs Grease characteristics Standard or Biodegradable See Technical Data Sheet in Appendix Principal Components and Features Grease Pump s Available for 12 VDC or 24 VDC electrical systems s Pistons type activation for highly efficient grease delivery s Relief and check valves to prevent overpressure and backflows Grease Reservoir s Specially designed to connect with our special cartridges accordion type to minimize risk of grease contamination when refilling s Uses grease agitator for maximum efficiency Low level sensor to help preventing unexpected shut downs Grease Cartridges s Developed in our laboratories for the sole use of the ENVIROSYS system s Each cartridge weighs 2 kg approximately 4 4 lbs and is available in boxes of four units each s Available in two types highly adhesive standard and biodegradable chain greases for both summer and winter conditions Operator interface s Touch screen capability s Uses to oversee and control the chain grease lubrication process e Allows flow rate control for optimum lubrication Warning light and audible alarm to indicate time for refilling s Control up to two saws and one roller equipment s Use upgrade software version from SD card Electronic control unit s Contains state of the art controller to oversee all operations s Contains necessary electric protective fuses Electrical Cables a
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