MLP2 - DUAL-BRANCH LUBRICATION SYSTEM

Transcription

1 - DUAL-BRANCH LUBRICATION SYSTEM TABLE OF CONTENTS 1 GENERAL SYSTEM DESCRIPTION General information on automatic centralized lubrication system SYSTEM DESIGN SYSTEM OPERATION PUMPING UNIT Design Filling the lubricant reservoir of the pumping unit Use of filling device (Safematic code ) Technical specification Technical data Electrical safety Connections Symbols Spare parts USER INTERFACE IF-103-CH General description Design LED-signals Buttons Display Operation Display powersave mode Interval counting Pressurization Extra lubrication Phase codes for normal mode and alarm mode Normal mode displays Branch pressure displays Power failure Alarms Low level alarm Settings General Entering password...10

2 5.6.3 Entering settings SYSTEM MONITORING General Regular inspections SYSTEM TROUBLESHOOTING System troubleshooting User interface does not operate User interface triggers an alarm A lubrication point gets too little lubricant or nothing at all A lubrication point gets too much lubricant Warnings Contact information APPENDICES

3 1 (12) - DUAL-BRANCH LUBRICATION SYSTEM 1 GENERAL SYSTEM DESCRIPTION 1.1 General information on automatic centralized lubrication system Accurate lubrication prevents damages and shutdowns caused by inadequate lubrication. The service life of process equipment and machinery is extended and energy consumption and the used amount of lubricant are reduced. Thanks to automation, optimum lubrication is achieved and the burden on the environment is minimized. All this brings savings. Automation increases work safety, as equipment and machinery does not have to be lubricated manually during operation. In addition to all this a centralized lubrication system increases the runnability of production processes. 2 SYSTEM DESIGN Note Numbers in brackets are part numbers in the drawing system consists of a pumping unit (pos.1), a user interface IF-103-CH2 (pos.2), two pressure sensors (pos.3), lubrication branches (pos.4 and pos.5), dosers (pos.6) and possible check valve (oil lubrication system ) (pos.7). 3 SYSTEM OPERATION Dual-branch lubrication system () is a MultiLube application in which lines 1 and 2 operate as two lubrication branches. Single-line dosers can be used in the system, e.g. B-, OSand/or LG-dosers. Both branches have independent time- and pressure settings and interlocking inputs. User interface is IF-103-CH2. When pressurization starts in a lubrication branch, control unit starts the pump and opens the line valve of the branch in question. The pump stops when pressure exceeds the set high limit and starts, when the pressure goes below the set high limit. After the set pressurization time, the system control stops the pump and pressure discharges from the branch to the lubricant reservoir. If the lubricant level in the reservoir drops to the low limit level during pumping, the reservoir low level switch sends an alarm to the control unit and pumping is stopped. The alarm can be disabled by filling the lubricant reservoir and resetting the alarm. Note The branches can not be pressurized simultaneously. Caution In an oil lubrication system the viscosity of used oil must be min. 46 cst in pumping unit operation temperature.

4 2 (12) Caution Check valve EOS-CV must be used in an oil lubrication system. The check valve prevents the piping from draining during interval. See drawing Note External pressure transmitters or pressure switches can not be used in an -system. Note Lubrication history data properties are not in use. 4 PUMPING UNIT 4.1 Design Note Numbers in brackets are part numbers in the drawing Pumping unit comprises of a body (pos.1) and a lubricant reservoir (pos.2). The body comprises of a pumping element (pos.3), an electric motor (pos.4), a line valve (pos.5), a pressure relief valve (pos.6), a heating element (pos.7) and a power supply (pos.8). Pumping unit is controlled by a user interface (pos.9) and a circuit board (pos.10). Pumping unit is equipped with a pressure sensor (pos.11) for each branch. Lubricant reservoir is equipped with a follower piston (pos.12), a level indicator (pos.13) and a low level switch (pos.14). Filling connector (pos.15) of the lubricant reservoir is equipped with a filter (pos.16) and a safety valve (pos.17). Pumping unit is equipped with a supporting block (pos. 18). 4.2 Filling the lubricant reservoir of the pumping unit Lubricant reservoir of the pumping unit is filled through the filling connector which is equipped with a filter Use of filling device (Safematic code ) Note Numbers in brackets are part numbers of drawing A. 1. Ensure that the surroundings of the pumping unit are clean. Impurities in the system prevent trouble-free operation and cause damage when reaching the lubrication point. 2. Remove the lid from the lubricant reservoir (1) and press the follower plate (2) tightly to the reservoir above the lubricant. Follower plate is not used with fluid lubricants, as it does not remain on the surface. 3. Place the lid (3) on top of the lubricant reservoir. Fasten the lid with wing screws (4) on the lubricant reservoir. 4. Place the pump (5) through the lid into the follower plate central unit (6). 5. Connect the lubricant hose (7) to the pump. 6. Fill the lubricant hose by pumping by hand. 7. Connect the quick connector (8) to the lubricant hose. 8. Connect the quick connector to the pumping unit filling connector (9).

5 3 (12) 9. Fill the lubricant reservoir of the pumping unit by pumping slowly by hand. 10. Filling of the lubricant reservoir can be followed at the level indicator (10). To prevent overfilling, the pumping unit is equipped with a safety valve (11). 11. Turn the pump handle (12) to upright position so that pressure discharges to the lubricant reservoir. 12. Disconnect the quick connector from the pumping unit filling connector. 13. Fasten the protecting cap (13) of the pumping unit filling connector. 14. Fasten the protecting cap (14) of the filling device quick connector. Caution Filter (15) of the filling connector has to be cleaned regularly and replaced if necessary. 4.3 Technical specification Technical data Quantity Value Unit Description t C Operation temperature p max 250 bar Maximum pressure U 115 AC or 230 AC V Power input P 150 W Power consumption 13 g/min Pump capacity V 4 or 10 l Reservoir volume m Aluminium 360 x 538 x x 720 x 246 (w x h x d) IP65 kg mm Weight, full 4 l reservoir Weight, full 10 l reservoir Body material Dimensions, 4 l reservoir Dimensions, 10 l reservoir Protection class Electrical safety Note Check supply voltage from the pump name plate (115 or 230 V AC). Pump is equipped with a 3 m power cord for connecting to the electrical network. Connection to the network is made next to the pump with a plug or by using a connection box equipped with a 2-pole switch (for example Safematic code ) Connections Outputs lubricant, 2 pcs, female thread R 1/4 or NPT 1/4

6 4 (12) Symbols MLP-A-B-C-D Abbreviatio n Description : MultiLube pump, 2-branch application A: 4 Lubricant reservoir volume, 4 l 10 Lubricant reservoir volume, 10 l B: 1 Number of lines, single-line system C: 115 Power input, 115 V 230 Power input, 230 V D: PSE Pressure control unit, built-in pressure sensor Example: PSE Pressure control unit, built-in pressure sensor Power input, 230 V Number of lines, single-line system Lubricant reservoir volume, 4 l MultiLube pump, 2-branch application Spare parts See -pumping unit spare parts (drawing no ).

7 5 (12) 5 USER INTERFACE IF-103-CH2 5.1 General description IF-103-CH2 is a user interface for dual-branch lubrication system. IF-103-CH2 user interface and built-in circuit board ST-103-CH2 contain application program for this purpose. User interface can be used to control a lubrication system with one or two branches. Lubrication programming, alarm resetting and lubrication event monitoring can be performed with the user interface. 5.2 Design Note Numbers in brackets are part numbers in the drawing The IF-103 user interface includes a display (pos.1), LED-signals for lubrication branches and pressurization (pos.2), browsing buttons (pos.3) and setting/function button (SET) (pos.4). The display shows information about one lubrication branch at a time. Branch is selected with display code br1 or br2. See paragraph Normal mode displays LED-signals LED-signal Description 1 Green LED-signal is lit when lubrication branch 1 is selected on the display. Red LED-signal is blinking, when lubrication branch 1 is in pressure alarm mode. Red LED-signal is lit when the branch has not been selected and it is in alarm mode. 2 Green LED-signal is lit when lubrication branch 2 is selected on the display. Red LED-signal is blinking, when lubrication branch 2 is in pressure alarm mode. Red LED-signal is lit when the branch has not been selected and it is in alarm mode. P Red LED-signal is blinking, when the pumping unit is in low level alarm mode.

8 6 (12) Buttons Button SET Description In normal operation mode, the button is used to browse set values on the display. In setting mode, the button is used to change the value on the display. In normal mode the button is used to select pressure display. In setting mode, the button is used to move to the next character of the display. When browsing the set values, the button is used to return to normal mode. In normal mode, the button is used to start extra lubrication, to stop lubrication or reset an alarm. In setting mode, the button is used to save the value that has been changed. When browsing the set values, the button is used to go to setting mode. When a button is pressed, all green LED-signals are lit for a moment. This indicates that information, that a button has been pressed, has been transmitted forward Display User interface has a display of 3 characters and 3 decimal points. 5.3 Operation Display powersave mode In normal mode display shifts to powersave mode when the buttons have not been used for three minutes. In powersave mode only the decimal points are blinking on the display. Lubrication events are performed according to the set values. The display returns to normal mode if any button is pressed or if an alarm occurs Interval counting In normal mode the display shows the time elapsed since the last pressurization of the selected branch as hours and minutes. Green LED-signal of branch 1 or 2 indicates which branch has been pressurized last. Interval time is counted always, except when system is in alarm mode or turned off interlocking switch is closed system is turned off (maximum pressurization time = 0) Pressurization Pressurization time is shown on the display as seconds. Green LED-signal of branch 1 or 2 shows which branch is pressurized. Green LED-signal P indicates that pressurization is in progress. Pressurization can be stopped with SET button.

9 7 (12) Extra lubrication Extra lubrication can be started, if the system is not currently in alarm mode, turned off or pressurizing. Extra lubrication is started in normal mode with SET button, when the display shows time elapsed since the last pressurization. Extra lubrication can be stopped with SET button. New pressurization starts only after pressure in the branches is below the set low limit value. During pressure discharge display shows phase code dc Phase codes for normal mode and alarm mode In normal or alarm mode, the phase code corresponding to the program phase is shown on the display. Phase code dc Loc OFF AGr ALP AHP Description Pressure discharge waiting time (discharge) Interlocking switch is closed (Locked) System is turned off. Lubricant reservoir low level alarm (Alarm, Grease) Pressure low alarm (branch pressure does not rise high enough during pressurization time) (Alarm, Low Pressure) Pressure high alarm (branch pressure is not low enough when pressurization phase starts) (Alarm, High, Pressure)

10 8 (12) Normal mode displays Normal mode displays, which show lubrication program set values, can be browsed with button. Display codes change in the following order when -button is pressed. Display code Description br1, br2 Cou C P PLo PHi PrE SPE *) brc *) res *) The lubrication branch selected on the display. Press SET-button to move to another branch when the code is displayed. (branch) Lubrication cycle counter. (Cycle Counter) Counter reading is added by one unit when lubrication ends. Decimal point is used to separate thousands. Lubrication cycle set value [h.mm] (Lubrication Cycle) Maximum pressurization time set value [s] (Lubrication, Pressurization time) Low limit pressure set value [bar/psi] (Pressure, Low limit) High limit pressure set value [bar/psi] (Pressure, High limit) Selection of pressure unit (Pressure unit) bar or psi Selection of customer-specific special functions (Special) Number of lubrication branches (branch Count) 1 or 2 Restoring the factory settings (Reset) *) A separate password is required for browsing and setting these parameters. Decimal points are used to separate thousands on lubrication cycle counter reading. Counter max. reading is 49.9 = According to lubrication system basic settings pressure unit in the display is bar or psi. In psi reading decimal points are used to separate thousands. For example 1.02 = 1020 psi.

11 9 (12) Branch pressure displays Branch pressure displays can be selected with -button. Pressing the button will show the branch 1 pressure display first. Code P1 and branch 1 pressure display are displayed in turns. Pressing the button again will show the branch 2 pressure display. Code P2 and branch 2 pressure display are displayed in turns. If branch 2 does not exist, program returns to show the phase code. From branch 2 pressure display program returns to display phase code by pressing -button. If signal from pressure sensor is not detected code _ is displayed. 5.4 Power failure The set values and program status are preserved in the memory also during power failures. After power is back on, the operation will resume from the status it was before power failure occurred. Possible stopped pressurization restarts for the same branch. Interval time is not counted during power failures. 5.5 Alarms The system is in alarm mode when the red LED-signal for branch 1, branch 2 or pressurization P is blinking Low level alarm The system triggers a low level alarm, stops pressurization and goes into alarm mode, if the lubricant reservoir is empty. This means that the reservoir low level switch is closed. Code AGr is blinking on the display and the red LED-signal P for pressurization is blinking. The same branch will be pressurized again, when low level switch is open and the alarm has been reset by pressing the SET button. 5.6 Settings General Set values are lubrication system basic values, for example pressure settings. All settings are password-protected.

12 10 (12) Entering password 1. Select the code for the setting to be changed on the display with -button. 2. Press SET button. 3. Display shows code PPP. 4. In a moment the first character of the display starts to blink. 5. Select with -button the first number of the password on the display. 6. Move to the next character with -button. 7. When all three numbers of the password have been entered, press SET button. 8. When password has been entered correctly, code ACC is displayed. If the password has not been entered correctly, code Err is displayed and display returns to normal mode. Note Set value password is Entering settings 1. Select the code for the setting to be changed on the display with -button. 2. Press SET button. 3. The first number of the value to be set is blinking on the display. 4. Select the desired number with - button on the display. 5. Move to the next number with -button. 6. The set value is saved in the memory with SET button. 7. Exit setting mode with -button. The display returns to normal mode automatically after 4 minutes if the buttons have not been used. 6 SYSTEM MONITORING 6.1 General Regular monitoring is a prerequisite for faultless system operation. Warning Ensure that there is no pressure in the system during maintenance procedures. 6.2 Regular inspections Daily inspections control unit for trouble-free operation Monthly inspections check piping in locations which are exposed for external damages

13 11 (12) 7 SYSTEM TROUBLESHOOTING 7.1 System troubleshooting User interface does not operate Operation disturbance Cause of operation disturbance Solution Display and LED signals of user interface are not lit. No supply voltage on pumping unit. Check supply voltage User interface triggers an alarm Operation disturbance Cause of operation disturbance Solution The red P LED-signal is blinking at the user interface. The red LED-signal for lubrication branch is blinking at the user interface. Alarm, low pressure on display. Pressure is below the set pressure high limit value. Pressure drops below the set low limit during lubrication phase. The red LED-signal for lubrication branch is blinking at the user interface. Alarm, high pressure on display. Lubricant reservoir is empty. Header piping leaks. Pumping element is damaged. In a 2-branch system the pressure has not dropped in the branch which was pressurized last. Fill the lubricant reservoir. Reset the alarm. Locate and repair the leakage. Pressure does not discharge to the reservoir. Check the operation of the line valve in the pumping unit. 7.2 A lubrication point gets too little lubricant or nothing at all Operation disturbance Cause of operation disturbance Solution The rotation of the bearing makes noise, is trembling or the temperature is rising. Doser does not operate Grease leakage in the area of lubrication piping. The dosage adjustment of the doser is too small. The lubrication point has clogged. Lubrication pipe or hose has clogged. The doser is damaged. Lubrication piping between the doser and lubrication point is damaged. Increase the dosage. Clean the lubrication point. Clean or replace lubrication pipe or hose. Replace the doser. Check and repair the lubrication piping.

14 12 (12) 7.3 A lubrication point gets too much lubricant Operation disturbance Cause of operation disturbance Solution Considerable grease leakage in the lubrication point. The temperature of the bearing rises. The dosage adjustment of the doser is too large. The doser is damaged. Adjust the dosage to a smaller amount. Replace the doser. 7.4 Warnings Caution The lubrication disturbances of the critical lubrication points must be repaired immediately, since inadequate lubrication rapidly damages the equipment or machinery being lubricated. Note In the event that the operation disturbance can not be repaired with the help of these instructions, please contact the supplier immediately. 7.5 Contact information Oy SKF Ab P.O. BOX 80 FI MUURAME FINLAND Tel Fax WWW:

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