Precision Lubrication

Transcription

1 TP & LP Automatic Pumps Precision Lubrication Automatically dispense the right amount of grease to all critical lubrication points at the right time Improve equipment reliability, reduce costly downtime and eliminate lubricantrelated failures Extend equipment and component life, prevent premature replacement of parts and machinery Optimize manpower resources, reduce labor and unscheduled overtime costs Reduce lubricant consumption, generate less waste Reduce operating costs and increase company profitability Simple, Efficient, Economical. 0 Bosworth Street, West Springfield MA

2 Table of Contents General Description of Operation, Applications and Features TP and LP Automatic Pumps - Technical Data Pump Connector Timer Control PC Board Desmodromic Pumping Element Pressure Gauge and Pressure Relief Valve Progressive Distributors Progressive Distributors - Technical Data and Dimensions Progressive Distributors - Outlet Configurations Tubing and Fittings Periodic Maintenance and Troubleshooting, , 4, 6, West Springfield MA

3 Series Progressive Lubrication Systems - General Description of Operation LP and TP Lubricators dispense the precise amount of grease required by each critical lubrication point at field-adjustable intervals, while the machine is in full operation. This precision application forms a consistent and reliable barrier against moisture, dirt and corrosion to protect valuable equipment and components, reduce labor and lubricant costs and increase over-all profitability. Grease is loaded into the pump through a zerk fitting (or, preferably, a QD-type coupler or cam lock). An electric motor drives a vertical shaft coupled to a specially designed paddle that scrapes the inside of the reservoir and pushes the grease down into the cam driven, positive displacement pumping element. Competitive pump designs use a spring on the pumping element which can fatigue, break or lose tension. Lubrication Technologies pumps utilize a desmodromic element that is both pushed and pulled by the cam. This eliminates the need for a return spring while ensuring consistent delivery of the lubricant through the main distributor block to the secondary distributors. Each distributor divider valve is configurable to deliver the precise amount of grease required by each component at optimum intervals. Applications LP Lubricators are equipped with.8 or.7 liter reservoirs and V AC/DC electrical motor, ideal for: Rolling Stock including Dump Trucks, Tractors and Trailers, Sweepers, Cement Mixers and Mini-excavators Industrial Machinery TP Lubricators are equipped with 4, 6, 8 or 0 liter reservoirs and 4V AC/DC electrical motor; ideal for: Rolling Stock including Excavators, Wheel Loaders, Screeners and Crushers Industrial Machinery Both systems are highly configurable with multiple options including an integrated timer, and up to three additional pumping elements (each equipped with pressure guage and relief valve) and can be used with a variety of NLGI grease grades (depending on operating temperature, the speed at which the component is moving and the load placed on the component. Refer to pg. and to the Troubleshooting guide on pg. 6 for important information on selecting the best grease, considering operating conditions.) West Springfield MA

4 LP/TP Features and Benefits Simple to use, competitively priced, extremely efficient and virtually maintenance free, LP and TP Systems reliably and consistently deliver the precise amount of grease needed at each lubrication point at the intervals required for optimum performance while the machine is in motion. Improve equipment reliability, reduce costly downtime and eliminate lubricant-related failures Extend equipment and component life, prevent premature replacement of parts and machinery Optimize manpower resources, reduce labor and unscheduled overtime costs Reduce lubricant consumption, generate less waste Reduce operating costs and increase company profitability Pos. Description. Acrylic Reservoir Tank 6 4 LP -.8,.7 TP - 4, 6, 8 or 0 liters. Reservoir Tank Lid (Powder-coated Aluminum). Male Quick Disconnect Fill Connection 4. Desmodronic Pumping Element. Pressure Gauge 6. Pressure Relief Valve 7. Motor Housing (LP - Plastic; TP - Powder-coated Aluminum) 8. Push Button (with Optional Timer) 9. Electrical Plug to Pump Connector 0. PC Board - Min. Lube Time; Hours Delay Time West Springfield MA

5 LID O-RING SELF-LOCKING NUTS TIE ROD W/ THREADED ENDS RESERVOIR PADDLE NUT/BOLT SHIM MOTOR GRILL BEARING ECCENTRIC SHIM O-RING BEARING PUMP BODY PUMPING ELEMENT MOTOR HOUSING COVER O-RING TP and LP Technical Data LP TP Reservoir Capacity Grease* Relief Valve Setting Discharge/Minute per Outlet Outlets Outlet Connection Operating Temp Range* Operating Voltage Electrical Connections Grease Fill Connector IP Enclosure Rating.8,.7 liter.8 cc - V AC/DC 4, 6, 8, 0 liter NLGI No bar,, 4 cc mm tubing -0o to +80o C or 4V AC/DC DIN Connector Quick Disconnect IP 6 Motor Type External Fuse Duty Cycle Electrical (0 RPM) 7. AMP Minute Max Runtime * Lubrication Technologies highly recommends: Lubrication Engineers Almagard Vari-Purpose Lubricant 7 (NLGI ); a heavy-duty, multifunctional grease designed for exceptional mechanical stability, excellent extreme pressure and high temperature capabilities and superior impact resistance. Recommended for extended service applications, Almagard 7 is extremely tacky and will not wash off, pound out or melt and run, even in severe conditions. Almagard 7 performs well in a broad temperature range and has a dropping point of 60 C (00 F). Contains ALMASOL, LE s exclusive wear-reducing additive. Also contains QUINPLEX, LE s unique additive which contributes to outstanding water resistance, tackiness, enhanced mechanical stability, forms a barrier against corrosion and ensures thorough coupling of oil with the grease base to prevent seperation and changes in consistency, even after being worked thousands of times.. Pump Connector (a.k.a. Hirschman Connection) ELECTRIC MOTOR MOTOR HOUSING BASE MOTOR HOUSING WITH PC BOARD PUMP CONNECTOR Pos... Wire +Blue -Brown Connection Positive Key Switch Negative Earth West Springfield MA

6 Timer Control and PC Board To set the Lube and Delay intervals in the Timer Control: Remove the plastic cover on the Timer. The left side of the timer indicates the duration of time the pump is metering lubricant measured in minutes (Lube or Work time). The total range is to minutes. The right side of the timer indicates the duration of time the pump is in Delay mode (Delay or Break time). The range is. hour to 8 hours in / hour increments. To increase the volume of lubricant delivered to all components served by the system, increase the Lube time and/or decrease the Delay time. To decrease the volume of lubricant delivered to all components served by the system, decrease the pump Lube time and/or increase the pump Delay time. Replace the cover on the Timer, making note of whatever changes have been made. The pump will power up when the vehicle ignition is turned on and the LED will show red for approximately seconds while an automatic system check is performed. Assuming the check is normal, the LED will turn green and the pump will operate according to the Lube/Delay settings. See pg. 7 for PC Board Technical Characteristics and additional explanations of LED displays. When the vehicle ignition is turned off, the Delay time is stored and counting resumes when the vehicle ignition is started again. Note: Pressing the Manual Cycle Button once over-rides the Timer Control and makes the pump run for whatever interval has been set for the Lube time. Pressing and holding the Manual Cycle Button for 0 seconds will initiate a continuous cycle and the pump will not shut down until the vehicle ignition is shut off. 4 Break time (hours) Work time (min.) Operating CONTROL PANEL TP 4 PC Board on Timer Control Lube/Delay adjustment pins turn counter-clockwise Pos. Description.. Timer Control LED (Red during minute system check, Green during operation; see pg. 8 for additional LED displays). Lube Adjustment; - minute intervals possible (= minutes; 4=4 minutes; etc. up to minutes) 4. Delay Adjustment;.0 to 8 hour intervals possible (.=0 minutes; = hour;.=. hours; etc. up to 8 hours). Manual Cycle Button: Press once to initiate the Lube cycle Press and hold for 0 seconds to operate continuously until ignition shut-off West Springfield MA

7 Timer Control PC Board Technical Specifications Working voltage 0/0 VDC Maximum continuous current Motor short circuit limit A standard 0 A maximum Working temperature -o +80o C Hardware protection - Motor overload limit - Polarity inversion - Overheating - Overvoltage (max 4V) Type of time storage memory EPROM Memory duration Unlimited (no battery to replace) PC Board LED Function Displays Pump power up: Red LED flashing Pump in stand by: Fixed green LED Pump operating: Flashing green LED LED shows red for three seconds during system check, then green for operational. LED flashes red if anomoly is found during system check; troubleshoot. The pump is on and operational but not dispensing lubricant during scheduled Delay time. The pump is on and dispensing lubricant during scheduled Lube time; continues flashing green for the duration of the Working time. Button Functions Red button Press for seconds to perform manual greasing operation during a Delay interval. Press for 0 seconds to perform continuous greasing until vehicle ignition is turned off. When ignition is turned on again, Lube/Delay functions will resume as programmed. Removing The PC Board To remove the PC Board, open the Pump Housing by removing the M hex screws (see illustration right). Care must be taken to avoid damaging the electrical cables inside. Before replacing the Pump Housing, make sure that all parts are clean and dry. West Springfield MA

8 Desmodromic Pumping Element The illustration below shows the desmodromic pumping element. The piston fits into a groove on the cam which pushes and pulls the pumping element shaft, enabling pumping of the grease at the intervals specified in the Controller. The pumping element has a fixed grease flow rate determined by the diameter of it s piston. 4 4 Pumping Element Technical Data Pos Description Code Pumping element Pumping element housing Pumping element piston Available diameters: Grease flow rate in cubic cm p/min.: Non-return valve Pumping element mounting fitting TP00... Fixed flow rate Tempered steel Tempered steel with sealing system 4. mm diameter. mm diameter 6. mm diameter cc p/min. cc p/min. 4 cc p/min. Self-purging 9 mm diameter Replacement of Pumping Elements (Fig. )! Caution! This can be tricky...do not pull or push the piston straight into the cam groove. The paddle must be positioned 80o from the pumping element Slide the piston out from the pumping element housing (Fig. ) Hold the pumping element at a slight angle, couple the piston with the groove in the cam while bringing the pumping element level (Fig. ) Screw the pumping element clockwise (see Pos. ) using a 4 mm wrench until tight. Check for correct positioning by performing a manual lubrication cycle to verify that the scraper rotates properly. If scraper is not rotating, then the pumping element is not properly positioned within the cam groove. Remove the pumping element and repeat the assembly operation. (Fig. ) West Springfield MA

9 Pressure Gauge and Relief Valve The pumping element T-fitting is equipped with a pressure guage to monitor system pressure and a relief valve set at 80 bar. Optimum system pressure will vary according to application, ambient temperature and the type of grease used. Once those baseline measures are established, the gauge is a useful indicator of system performance. In the event of a blockage, hose rupture or other anomoly resulting in pressure in excess of 80 bar (blue numbers) or 4000 psi (black numbers), the relief valve will release grease to prevent rupture of piping and damage to components. The pumping element, pressure guage and relief valve configuration depends on the application. A common configuration is shown below Pos Description Pressure relief valve 80 Bar Pumping element mounting fitting 9 mm diameter Outlet fitting for 6 mm hose 7 mm diameter Fitting for Pressure Gauge Drilled directly into the relief valve Pressure Gauge Tubular spring manometer Ni Cr stainless steel body IP-6 mechanical protection Coper alloy measuring element in glycerine bath Radial or rear connector 7 See Ex. A on page 4 for explanation of tubing and fittings from Pump to Distributor. West Springfield MA

10 Progressive Distributors Each pumping element feeds a primary progressive distributor via a single line. The modular distributor is comprised of an inlet section and three to twelve dispensing elements, including an end section. INLET INLET SECTION Ex. A Ex. A shows a modular distributor block set up with an inlet section, two mid-sections with dispensing elements and an end section with dispensing elements. OUTLET 4 OUTLET OUTLET OUTLET Grease enters the inlet under pressure and flows to the right side of the piston in mid-section which pushes the piston and the grease to the left where it is ultimately dispensed through outlet. (Ex. A) The movement to the left of piston also opens the flow of grease through a gateway to the piston in section, where the lubrication cycle continues with grease ultimately dispensed through outlet. (Ex. B) Again, the movement to the left of piston opens the flow of grease through a gateway to the piston in section where the lubrication cycle repeats with grease dispensed through outlet. The movement to the left of piston opens the flow of grease through a gateway to mid-section, this time to the left of piston which pushes the piston and grease to the right where it is ultimately dispensed through outlet 4. The lubrication cycles repeats with grease pushing pistons and successively to the right, dispensing grease successively through outlets and 6. OUTLET OUTLET 4 OUTLET INLET INLET SECTION OUTLET 6 Ex. B OUTLET OUTLET Note: For purposes of this explanation, the movement of grease through piston is shown separately from the movement of grease through piston. In actual fact, the movement of grease through the lubrication cycle is continuous during a programmed Work Interval. OUTLET OUTLET West Springfield MA 0089 Any outlet on the primary distributor may connect to one or more secondary distributor blocks, each of which operate in the same way. Since the movement of one piston is the necessary condition for the movement of the next piston (and so on), all progressive distributors are connected in series. This means that a blockage in any dispensing element, no matter which distributor block it occurs in, will cause the whole system to block. This progressive series design allows a single pressure gauge and relief valve to serve the entire system and alert personnel to a non-delivery issue.

11 Progressive Distributors (cont.) - Technical Data and Dimensions INLET SECTION WITH GREASE NIPPLE MID SECTION MID SECTION MID SECTION MID SECTION 4 MID SECTION MID SECTION 6 MID SECTION 7 MID SECTION 8 Divider sections are carbon steel with a tempered steel internal piston. Dispensing elements are available with flow rates of 0.00, 0.07, 0.0, or 0.6 cm for each outlet*. The seal between the various elements is formed by high resistance O-Rings. Progressive Distributor Elements Technical Specifications Operating pressure Working temperature From to 00 bar From -0 to +80 C with standard O-rings Flow for single outlet Material 0.0 cc, 0.7 cc,.0 cc,.6 cc* Electroless nickel plated steel No. cycles per minute 00 max. Inlet connection M 0x Outlet connection M 0x Fixing screws x4 No. of dispensing elements to (including end section) * Flow rates can be increased by combining outlets, see pg. MID SECTION 9 MID SECTION 0 MID SECTION END SECTION Dimensions of Divider Sections TOP VIEW mm 0 mm mm No. of Elements Height (mm) LEFT SIDE VIEW. mm mm mm M 0x FRONT VIEW 7. mm. mm M 0x 7 mm 6. mm. mm West Springfield MA

12 Progressive Distributors (cont.) The modular inlet section, multiple mid-sections and end section are held together with two tie rods inserted from the top and then secured with cap screws and ferrels. A centering pin keeps the blocks aligned during assembly. The seal between the various elements is completed with high resistance O-rings Pos. Description.. Inlet section - no dispensing elements Mid-section - two potential dispensing elements. 4. Mid-section - two potential dispensing elements End section - two potential dispensing elements. Tie-rods Cap screw Ferrule Ex. C PORT PIN Outlet Configurations: Ex. C - Two Outlets Per Dispensing Element There are two outlets on every dispensing element (mid-sections and end-sections). Ex. D EX. C & D - CROSS SECTION VIEWS: MID-SECTION BLOCKS, AS SEEN FROM THE BOTTOM PLUG Ex. D - One Outlet Per Dispensing Element One outlet can be blocked by removing the port pin (see Ex. C) from the left side outlet (using a mm Allen wrench) and then fitting a plug into that outlet (see Ex. D). This doubles the volume of that section and shunts the grease to one outlet. Ex. E Ex. F EX. E & F - CROSS SECTION VIEWS: MID-SECTION BLOCKS, AS SEEN FROM THE SIDE Ex. E - Three Combined Outlets/One Independant Outlet In Two Stacked Dispensing Elements In Ex. E, three outlets have been combined by removing the port pin in the top dispensing element and using a steel bridge so that the top left, top right and bottom right outlets function as one, with a flow rate equal to the sum of the three single outlets. (The outlet at bottom left, with port pin intact, continues to function independantly.) Ex. F - Four Combined Outlets In Two Stacked Dispensing Elements In Ex. F, all four outlets have been combined by removing the port pins in both dispensing elements, plugging the outlet at bottom right and using a steel bridge so that all outlets function as one, with a flow rate equal to the sum of the four single outlets. See photos page West Springfield MA

13 Outlet Configurations (cont.): Fig. A Fig. A (right) shows the front and side view of a progressive series distributor with: Inlet section Mid-section one with a bridge combining three outlets; lubricant flows to the left outlet in midsection two, tripling the lubricant flow rate at that left outlet Mid-section two with a bridge combining three outlets, lubricant flows to the right outlet in the end section, again tripling the lubricant flow rate at that right outlet. INLET OR END SECTION WITH FITTING FOR DISTRIBUTOR PUMP END SECTION WITH PROXIMITY CONTACT CC available npn or pnp West Springfield MA

14 High Pressure Hose and Fittings - Pump to Distributor Blocks - 8 mm Ex. A 4 Pos. Part No... FR FR FR FR FR-00-0 Description High pressure hose; flexible, multi-layered; black; bar;,000 psi; OD - 8, ID - 6 Threaded sleeve; steel (galvanized surface); 8 mm L; mm sw; reverse thread over 8 mm hose outer shell 4o Tube socket; steel (galvanized surface); mm h x mm L; 0 mm sw; da 6 mm 90o Tube socket; steel (galvanized surface); 8 mm h x 7 mm L; 0 mm sw; da 6 mm Straight tube socket; steel (galvanized surface); 0 mm L; 0 mm sw; da 6 mm Hose and Fittings - Distributor Blocks to Secondary Distributor Blocks and/or Lubrication Points - 6 mm Fittings for tubing from distributor blocks to lubrication points vary widely depending on the application. Part numbers are given for this example only. Please call Lubrication Technologies for assistance with specific part numbers for 6 mm hose and fittings. 4 Ex. B 4 4 Pos. Part No. Description Polyamide tube; semi-rigid; black; 89 bar; 90 psi; OD - 6, ID - 4. M0/ /8 NPT x 6mm Straight (M0/ /8 NPT x 6mm Elbow also available, not shown above). 4. FR Ferrule Coupling Nut. 97-A (-) Numbered yellow flags placed on the distributor end and the lube point end of tubing for diagnostics West Springfield MA

15 xxx xxxx xxx xxxx xxx xxxx xxx xxxx Hose and Fittings - Distributor Blocks to Secondary Distributor Blocks and/or Lubrication Points - 4 mm Fittings for tubing from distributor blocks to lubrication points vary widely depending on the application. Part numbers are given for this example only. Please call Lubrication Technologies for assistance with specific part numbers for 4 mm hose and fittings. Ex. C 4 4 Pos..... Part No A (-) Description Polyamide tube; semi-rigid; black; 89 bar; 90 psi; OD - 4; ID - Push-lock straight connector (plated brass) Push-lock elbow connector; (plated brass); 90o angle Numbered yellow flags placed on the distributor end and the lube point end of tubing for diagnostics Ex. D Ex. D shows an exploded view of the pumping element connected to a Primary Distributor Block using a 90 degree tube socket at both the pumping element and the inlet section of the Primary Distributor Block; two threaded sleeves and 8 mm hose. The Primary Distributor Block is then connected to a Secondary Distributor Block (and two lubrication points) using push-lock straight and elbow connectors and 4 mm hose. The yellow identifying tags are used at each end of the hose to ease diagnostics. (See the troubleshooting guide on pg xxx xxxx xxx xxxx West Springfield MA

16 Periodic Maintenance! This manual is intended as a reference tool for the operation and preventative maintenance of the LP and TP Automatic Lubrication Systems. Preventative maintenance typically involves inspection of grease levels, minor adjustment of Lube and Delay intervals, confirmation of accurate grease dispensing at all lubrication points and identification of blockages and/or broken or loose lubrication lines. All other repairs and replacement of parts must be undertaken by certified technicians. The buyer assumes all risk and liability arising out of his or her repairs to the original product or it s parts. The reservoir will be filled after installation. When refilling the reservoir: Use only approved lubricant and consider operating and ambient conditions (see the note on pg. ) It is extremely important to use clean lubricant and clean filling tools; contamination is a primary cause of pump failure! Do not overfill! (/ to of space between the top level) Each LP or TP pump is equipped with a Male Quick Disconnect Fill Connection for use with a pail pump. A cam lock is available for manual filling methods, on request. Any air is vented during filling. Perform regular visual inspection of components: Take note of the pressure gauge reading. It will vary depending on the ambient temperature, number of lubrication points in the system, and the lubricant used. Higher than normal readings may indicate lubricant delivery issues. The pressure relief valve will release lubricant at approximately 4,000 to 4,00 psi. Troubleshoot readings in excess of 4,000 psi. The Timer Control LED light will show green when the pump is operational during a Delay interval and will flash green during a Lube interval The paddle will turn during each Lube interval. Use of the proper lubricant considering operating conditions is critical. Some lubricants will separate and harden; causing blockages, ruptured lines and loose fittings. Lubrication Engineers Almagard Vari-Purpose Lubricant 7 (NLGI ); a heavy-duty, multifunctional grease designed for exceptional mechanical stability, excellent extreme pressure and high temperature capabilities and superior impact resistance. Recommended for extended service applications, Almagard 7 is extremely tacky and will not wash off, pound out or melt and run, even in severe conditions. Almagard 7 performs well in a broad temperature range and has a dropping point of 60 C West Springfield MA

17 Troubleshooting Symptoms Possible Causes Interventions Pump does not operate Paddle does not turn LED lights not on Blown fuse Loose electrical connection Corrosion on connections Condensation on PC Board Corrosion on PC Board Pumping element is not coupled Defective motor Replace fuse Repair or replace wire Replace connection Remove PC Board, dry out and replace Remove PC Board, replace Reinstall pumping element Repair or replace the motor The pump operates but no lubricant is dispensed no indication of high pressure in the system LED flashes red The pump operates but no lubricant is dispensed Pressure gauge indicates high pressure Lubricant is expelled from pressure relief valve Reservoir low on lubricant Hardened or separated grease Air pockets in lubricant Corrosion on PC Board Defective pumping element Defective motor Dispenser is blocked Loose fittings or broken/crimped tubing Blockage in the system or valve has locked up Fill reservoir Clean and replace with approved grease* Refill and purge air Remove PC Board, replace Service or replace pumping element Repair or replace the motor Clean and replace with approved grease* Tighten all fittings; replace tubing Starting at furthest divider valve, use a hand-gun to grease the valve. If the valve does not take grease, there is a blockage at the lubrication point and/or the valve has locked up. Remove the plugs on the front face of the valve one by one. A sudden rush of grease from that port indicates that a blockage is present. Using the numbered identfication tags, find the lubrication point termination end and disconnect the line. Grease the block and/or install a fitting temporarily in place of the front plug and look for grease at the end of the tubing.! The use of a cordless grease gun or an air operated gun is discouraged. Use only a hand grease gun. Call your Lubrication Reliability Consultant with questions or concerns: David F. Piangerelli STLE Certified Lubrication Specialist #90 ICML, MLT II P: C: dfp@lubetechnologies.com Jamie D. Piangerelli Lubrication Reliability Specialist ICML, MLT I P: C: dfp@lubetechnologies.com Bruce A. Benson Lubrication Reliability Consultant ICML, MLT I P: C: dfp@lubetechnologies.com West Springfield MA