Operators Manual TTN LUBRICATOR Series Progressive 5580 r#9
Contents Precautions & Symbols... Manufacturer s Statement... General... Application... TTN Lubricator at a Glance... Technical Data...4 ISO Schematic...4 Wiring...5 Safety...6 Installation...6 Lubricator Operation...7 Controller Operation*...7 Controller Modes...8-9 Maintenance... 0 Troubleshooting... 0 How to Order... 0 Dimensional Schematics... Copyright Bijur Delimon International 008. Bijur Delimon International reserves the right to update or improve the technical specifications for this product without prior notice. BIJUR DELIMON INTERNATIONAL (99) 465 4448 LOCAL (800) 6 068 TOLL-FREE (99) 465 056 FAX WWW.BIJURDELIMON.COM 00 Gateway Centre Blvd., Suite 09 Morrisville, NC 7560 Precautions & Symbols The following symbols, used to identify safety instructions, are defined as follows: N Non-compliance will affect safety. Electrical safety is involved. Safe operation of the lubricator and/ or protection of the lubricator should be considered. Electrical connections made to Earth ground. Conditions and actions that pose hazards to the user. Electrical connections made to the neutral conductor are identified with the capital N All safety and/or warning labels affixed to the TTN Progressive Series Lubricators must be maintained in a completely legible condition. Also, any modifications made to the TTN Progressive Series Lubricators (or to any of its components) must be approved by Bijur Delimon International prior to its use; otherwise the warranty and any liability by Bijur Delimon International will be null and void. Manufacturer s Statement The manufacturer and/or distributor has provided the parts list and assembly diagram in this manual as a reference tool only. Neither the manufacturer or distributor makes any representation or warranty of any kind to the buyer that he or she is qualified to make any repairs or replace any parts to the product. In fact, the manufacturer and/or distributor expressly states that all repairs and parts replacements should be undertaken by certified and licensed technicians, and not by the buyer. The buyer assumes all risk and liability arising out of his or her repairs to the original product or replacement parts thereto, or arising out of his or her installation of replacement parts thereto. General TTN Lubricators are electrically driven piston pumps designed for use with series progressive systems. For injector systems refer to Datasheet #5547. These lubricators can be fitted with up to three independent piston elements providing positive displacement output to series progressive divider valves. TTN Lubricators are available with an integral programmable controller, low level switch and various reservoir capacities. Operating voltages are either or 4 VDC. Before installing this lubricator, please read this Operators Manual carefully. Failure to follow these instructions can result in damage to the product and/or serious bodily injury. The TTN Progressive Series Lubricator meets all of the operating parameters for Bijur Delimon series progressive centralized lubricating systems. You will need this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep this manual and invoice in a safe and dry place for future reference. Application TTN Lubricators are ideally suitable for off road mobile machinery such as loaders, excavators, articulated trucks, graders, etc. These lubricators are designed to work in conditions found in the construction, mining and forestry industries. A unique reservoir design keeps out contamination and prevents condensation from forming, thus assuring reliable automatic lubrication of critical wear points such as bearings, bushings and pins. BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9
TTN Lubricator at a Glance RESERVOIR EXTERNAL RELIEF VALVE PISTON ELEMENT RESERVOIR FILLING VALVE ELECTRICAL PLUG (MALE) ELECTRICAL PLUG (FEMALE) CONTROLLER (OPTIONAL) POWER RUN ALARM S R LOW LEVEL SWITCH (OPTIONAL) DC MOTOR The various TTN Lubricator models available differ from each other in reservoir sizes, relief valve settings, voltages and controller options. Refer to the How to Order section for available options. BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9
Grease used in system must be pumpable at the temperatures referenced. Contact lubricant manufacturer with specific questions. Electrical Connections Specifications Number of contacts: +PE Wire gauge: AWG 0-4 Cable diameter: 6-9.5mm Screw termination IP Enclosure Rating: IP-67 European version is /4 BSPP. See notes on page 9. Technical Data Lubricator Reservoir Capacity, 4 and 8 liter (4, 8 and 6 lb) Grease NLGI grade 000, 00 & 0 Relief Valve Setting 600 psi (48 bar) Discharge/min. 8cc (0.5 cu. in.) per element/outlet Outlets outlet maximum Operating Temperature Range - F to F (-5 C to 50 C) Operating Voltage or 4 VDC Pump Cam Rotary Speed 4 rpm Low Lubricant Level Switch amp Electrical Connections Binder RD4 Outlet Connection /4 NPT Grease Fill Connector Hydraulic quick disconnect IP Enclosure Rating IP-65 Controller (Optional) Loading Power 70 W Fuse VDC 8 amp 4 VDC 5 amp ISO Schematic CONTROLLER F M TTN PROGRESSIVE SERIES LUBRICATOR 4 BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9
Wiring With Controller & Low Level Switch (SC) With Controller & Without Low Level Switch (C) INTERNAL WIRING INTERNAL WIRING BINDER MALE SOCKET CONNECTOR BINDER FEMALE SOCKET CONNECTOR BINDER MALE SOCKET CONNECTOR BINDER FEMALE SOCKET CONNECTOR RED YELLOW BLUE BLACK RED BLUE YELLOW BLACK RED YELLOW BLUE BLACK RED BLUE YELLOW BLACK EXTERNAL CUSTOMER SUPPLIED WIRING EXTERNAL CUSTOMER SUPPLIED WIRING POWER SUPPLY FEMALE BINDER PLUG CONNECTOR LED MALE PLUG CONNECTOR EXTERNAL CYCLE COUNT OR PRESSURE SWITCH MECHANICAL CONTACT SWITCH WIRES FEMALE BINDER PLUG CONNECTOR POWER SUPPLY LED MALE PLUG CONNECTOR EXTERNAL CYCLE COUNT OR PRESSURE SWITCH MECHANICAL CONTACT SWITCH WIRES EXTERNAL ALARM INDICATOR LIGHT (LED) [OR RELAY 00 ma MAX] LOAD PROXIMITY SWITCH WIRES NPN TYPE BROWN BLUE BLACK EXTERNAL ALARM INDICATOR LIGHT (LED) [OR RELAY 00 ma MAX] LOAD PROXIMITY SWITCH WIRES NPN TYPE BROWN BLUE BLACK Without Controller & With Low Level Switch (S) INTERNAL WIRING Without Controller & Without Low Level Switch (N) INTERNAL WIRING BINDER MALE SOCKET CONNECTOR INTERNAL LOW LEVEL MECHANICAL MOMENTARY CONTACT SWITCH WIRES NO BINDER FEMALE SOCKET CONNECTOR PRESENT ON PUMP MOTOR ENCLOSURE BINDER MALE SOCKET CONNECTOR NO BINDER FEMALE SOCKET CONNECTOR PRESENT ON PUMP MOTOR ENCLOSURE RED BLUE BLACK BLACK RED BLACK EXTERNAL CUSTOMER SUPPLIED WIRING SHOWN WITH SMDC (MOBILE) CONTROLLER EXTERNAL CUSTOMER SUPPLIED WIRING SHOWN WITH SMDC (MOBILE) CONTROLLER FEMALE PLUG CONNECTOR FEMALE PLUG CONNECTOR 4 5 6 7 8 BIJUR DELIMON SMDC CONTROLLER 46M 4 5 6 7 8 BIJUR DELIMON SMDC CONTROLLER 46M NOTE: REFER TO SMDC INSTRUCTIONS FOR ACCESSORY COMPONENT WIRING SPECIFICATIONS NOTE: REFER TO SMDC INSTRUCTIONS FOR ACCESSORY COMPONENT WIRING SPECIFICATIONS EXTERNAL CUSTOMER SUPPLIED WIRING SHOWN WITHOUT SMDC (MOBILE) CONTROLLER EXTERNAL CUSTOMER SUPPLIED WIRING SHOWN WITHOUT SMDC (MOBILE) CONTROLLER FEMALE BINDER PLUG CONNECTOR POWER SUPPLY LOAD CONNECTIONS TO LOW LEVEL MECHANICAL SWITCH LOAD A MAX BROWN LOAD BLACK BLUE CONNECTIONS TO LOW LEVEL PROXIMITY SWITCH WIRES NPN TYPE LOAD TO BE LED OR RELAY 00 ma MAX FEMALE BINDER PLUG CONNECTOR POWER SUPPLY BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9 5
Safety This Operators Manual covers fundamental concepts, which are to be observed for installation, operation and maintenance. Therefore, it is absolutely necessary that the Operators Manual be studied by the person doing the installation prior to installation and start-up. It is also necessary to have this Operators Manual nearby and available for reference in the future. The safety instructions mentioned in this Operators Manual, as well as all national operating and safety regulations for the safe operation of such equipment are to be observed. Installation Before beginning the installation work, disconnect the electrical supply. Do not remove or modify any safety equipment currently installed on a construction machine or commercial vehicle. If necessary, this equipment can be temporarily removed during the installation of the TTN Lubricator.. Locate the TTN Lubricator away from heat sources.. Provide access to the lubricator for means of filling, cleaning and visual inspection.. Always adhere to installation instructions of the machine or vehicle manufacturer with regards to drilling and welding procedures. Observe minimum distances specified between holes and the upper and lower flange of the frame or between the holes. 4. Use drilling templates to locate and drill mounting holes. Mounting plates and templates are available for this product. When possible use existing mounting holes or studs. 5. Lubrication lines and electrical cable must be secured by means of clamps or straps to prevent them from rubbing or coming loose. Keep lines away from shocks, heat and areas subjected to stone and debris impact. For added protection lines or cables should be wrapped with appropriate loom or spiral wrap. Reservoir Filling Follow proper filling procedures: + + Use only approved lubricant; grease must be pumpable at the temperatures your equipment is subjected to. + + Use only new and clean lubricant and clean filling devices; dirt and other forms of contamination are a leading cause of pump failure. + + Use of either a manual or an automatic filling device is appropriate; care should be taken to avoid developing high grease pressure inside the bellows during the filling process. Overfilling the reservoir can lead to pump damage and risk of injury. During the initial filling process it is important to fill the reservoir (bellows design) to its maximum level, making sure all of the air present between the lubricant and the top plate of the bellows is exhausted from the reservoir. There is a vent hole located near the top of the center guide post (see drawing on right) through which the air is vented outside of the pump during filling. Air inside the bellows can lead to a low grease level condition that is not detected by the lubricator s low level switch. Initial Fill Condition Exhausting Air Reservoir Fill Complete Grease Air Bellows Vent Hole 6 BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9
Lubricator Operation Power supplied to a motor with gear box drives a precision eccentric cam which engages with up to three spring loaded piston elements. This action creates a suction and pressure stroke of the element(s), thereby displacing fixed volumes of lubricant through an outlet check valve. Lubricant is displaced through main line tubing or hose to a network of progressive divider valves. Each piston element comes with an adjustable external relief valve. Controller Operation* Keys Description S R Select Enter and reset Step selection Adjustment Controller Status LEDs Red Steady Yellow Flashing Green Steady None Lit Lubrication cycle Alarm Power supply on No input power to controller Set-up Mode With the controller energized: + + Press keys S and R simultaneously and release to enter control mode. + + The display panel will now show a fixed letter for the selected mode and a flashing number (-4). See page 8 for Controller Modes. + + To select the required mode press the key. + + Press the S key to advance to the next parameter of the selected mode. + + Repeat steps and 4 above using the key to move across the digits and the key to change the value of the selected flashing digit. + + On completion, press the R key to save the data and initiate a lubrication cycle. Manual Override + + With the controller energized press the R key to initiate a lubrication cycle. Program Review + + To review the preset data, press the S key repeatedly with the controller energized. + + To return to operating condition display, release S key or depress S key for 5 seconds. Fault Alarm + + In any alarm condition, e.g. low level, low pressure etc., the pump will not be able to operate and the alarm lamp will illuminate. The fault condition must be rectified to cancel the alarm and reactivate the system. * For optional controller versions. BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9 7
Controller Modes SET-UP MODE + R REVIEW PROGRAM S CONTROL MODE ~4 4 X RUN TIME ~999(S) X X X MONITOR X X X CYCLE X X X PRESSURE X X TIME COUNT COUNT ~999(S) ~999(C) ~99(C) HOLD PRESSURE ~99(S) X X X MONITOR TIME ~999(S) IDLE TIME ~9999(M) X X X X X X X PULSE ON ~99(S) PULSE OFF ~99(S) X X X X R RUN RETURN TO SET UP MODE Timer Control Mode (d ) Recommended for Systems without a Pressure Switch or Cycle Switch Low level alarm function enabled* In this mode, the lubricating system runs according to the preset run time and idle time. Pressure Control Mode (d ) Recommended for Injector Systems Pressure switch function enabled/ Low level alarm function enabled* A pressure switch installed downstream from the pump functions as the key monitoring device for the entire system. Normally the system will build up sufficient pressure required to activate the pressure switch (normally open) in a predetermined period of time (called monitor time) once the pump starts. The user can adjust the monitor time to a setting greater than the time required to satisfy the pressure switch (normally.5 times greater). If the system fails to reach sufficient pressure during that time period an alarm signal will be displayed (yellow LED on and EEPP appears on the digital readout). Possible causes for this type of alarm could be pump malfunction, broken supply line or crushed supply line prior to pressure switch. Lubrication intervals are adjustable from to 9999 minutes. An adjustable run delay(-99 seconds) following a pressure switch closure assures adequate pressure downstream from the pump. Cycle Control Mode (d ) Recommended for Progressive Systems Cycle switch function enabled/ Low level alarm function enabled* The cycle switch mounted on a progressive divider valve is the key monitoring device for the entire system. Normally when grease is being discharged from the outlets of the divider valve, a cycle pin engages with the switch, confirming a successful lubrication cycle. The controller can be programmed to allow for a predetermined number of cycle counts (-999). Once the preset number of counts is obtained the controller will stop the pump and revert back to the idle time setting (-9999 minutes). If the desired number of cycle counts is not obtained within a specified period of time (monitor time: -999 seconds), an alarm signal will be displayed (yellow LED on and EEcY appears on the digital readout). Possible causes for this type of alarm could be pump malfunction, divider valve malfunction, broken supply line or blocked supply line or feed line. Pulse Control Mode (d 4) Recommended for Pulse Systems Pressure switch function enabled/ Low level alarm function enabled* This mode is not applicable with the TTN Lubricator. Do not use. * For lubricators fitted with low level switch 8 BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9
Controller Mode Cont. Advanced Setup Mode In Advanced Setup Mode, additional features may be set to suit special application requirements. To enter Advance Setup Mode: PRESS AND HOLD KEYS. WHILE HOLDING, PRESS THE KEY. ADVANCED SETUP MODE S PRE-LUBE AT POWER ON Upon power on, lubrication resumes at last know position. (default) Upon power on, a lube cycle will initiate. (Pre-lube) FAULT RELAY STATE R Fault contacts (7,8) close during alarm condition. For use with alarm light. (default) Fault contacts (7,8) open during alarm condition. Failsafe, for use with PLC. RUN Fault Conditions: EEPP -Monitor time-out (Mode d - Injectors) Pressure switch did not activate within monitor time. EEHP -Pressure switch failure (Mode d - Injectors) Pressure switch was activate at the beginning of a lube cycle. Once customer fixes pressure switch - alarm will clear automatically. EEcY -Monitor time-out (Mode d - Progressive) Cycle switch did not activate within monitor time. EE -Internal memory failure (Checked at power up) No recovery. Turn off power and try again. If problem persists, replace control. EEFF -Bad program data (As read from EEprom at power up) Parameters have been found to be corrupted. To acknowledge, go to control mode (simultaneously press and R ). All parameters will need to be set to application requirements. Once parameters have been set, press R to save and return to operation mode. EEdF -Bad program data (Internal memory that holds program data has unexpectedly changed while in run mode) Upon acknowledge, (press R ) control resets and attempts to read memory from EEprom. Yellow LED -Low Level (Steady Yellow) Low lubricant level has been detected. BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9 9
Troubleshooting Symptoms Possible Cause Remedy No power to lubricator Blown fuse Replace fuse and check load Loose electrical connection Defective circuit board Incorrect wiring Repair or replace wire Replace circuit board Check polarity No grease delivery Reservoir low on grease Fill or top off reservoir Hardened or separated grease Defective pump element Air pockets in grease Defective motor Defective level switch Clean and replace with approved grease Service or replace element Refill and purge air Replace motor Replace level switch Insufficient pressure Faulty relief valve Replace relief valve How to Order Air pockets in grease Worn or defective pump elements Faulty check valve Loose fittings or broken tubing Name Voltage Reservoir Capacity Refill and purge air Repair or replace elements Replace check valve Repair or replace Options Part # TTN Progressive Lubricator VDC liter (4 lb) Low level switch TTNCS Low level switch & controller TTNCSC 4 VDC 4 liter (8 lb) Low level switch TTN4CS4 Low level switch & controller TTN4CSC4 8 liter (6 lb) Low level switch TTN8CS4 Low level switch & controller TTN8CSC4 Piston Elements --- --- --- 505-4 Other configurations available upon request. Contact Bijur Delimon for details. TTN Lubricators ship standard with one element. Additional elements can be purchased separately. Requires remote controller (See Datasheet #469: SMDC Controller). Maintenance TTN Lubricators require limited maintenance. Typically, scheduled PM programs allow for inspection of grease levels, broken or loose lubrication lines, and confirmation of grease distribution to all lubrication points. When performing any maintenance procedures on an automatic centralized system, attention should be paid to the cleanliness of tools, parts and filling devices. Dirt is a leading cause of system failures. When cleaning system components use petroleum spirits or benzene; do not use alcohol, acetone or similar solvents. Use only Bijur Delimon spare parts for the repair and refurbishing of TTN Lubricators. Lubricators should be returned to the factory for major repairs or any warranty work. Electrical circuit boards and related components should be properly packaged for shipments back to the factory. Failure to comply may void warranty. When ordering, specify by name, voltage, reservoir capacity, options and part number, e.g. TTN Progressive Lubricator, VDC, liter (4 lb), low level switch, Part #TTNCS. North American Element Code # s: C: Progressive, element, /4 NPT threads European Element Code # s: E: Progressive, element, /4 BSPP threads Accessories Description Part # Mounting plate (straight) 5455 Mounting plate (90 ) 5456 Pressure gauge (5000 psi, /4 NPT, LM) U90F Pressure gauge (000 psi, /4 NPT, LM) U90D Mating fill connector UX45 0 BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9
Service Parts: TTN Lubricator 9 7 See specific Piston Element parts on page. 0 4 5 6 7 8 S POWER RUN ALARM R Item # Description Part # Qty. O-ring 00-8 Bearing 50- Copper seal 5589-7 4 Fill connector 504 5 Shaft seal 78-6 6 Electrical plug: signal (male) 504-7 Electrical plug: power (female) 5040-8 Controller (4 VDC) 5896-SK Controller ( VDC) 5896-SK Item # Description Part # Qty. 9 Reservoir cover: liter (4 lb) 5668- Reservoir cover: 4 liter (8 lb) 5668- Reservoir cover: 8 liter (6 lb) 5668-4 0 Low level switch (mech.) 484- Low level switch (electric) 4965-7 Motor (4 VDC) 450-4 Motor ( VDC) 450-5 Bottom cover 49968- --- Fuse: 5 amp (4 VDC) 076- Fuse: 8 amp ( VDC) 076-4 BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9
/4 NPT threads: Part #505-4 /4 BSPP threads: Part #505-5 Service Parts: Piston Element Item # Description Part # Qty. Relief valve (600 psi) 474 4 Swivel connector 490 5 Outlet adapter 49-9 6 Copper seal 5589-5 Piston Element (Part #505-4) 4 5 6 Reservoir Sub-assemblies Item # Description Part # Qty. 7 liter (4 lb) 5647 4 liter (8 lb) 5647 8 liter (6 lb) 56474 * Includes all reservoir components and fastners, except reservoir cover. Each reservoir sub-assembly can be used to easily repair a damaged reservoir or convert reservoir capacity from one size to another. See image on page 0 (Item #) for the parts included in the reservoir sub-assembly. The reservoir cover is not included in the reservoir sub-assembly and must be purchased separately if needed. BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9
Dimensional Schematics Measurements shown in millimeters. MAX FILL H MIN FILL /4 NPT OUTLET (M) POWER RUN ALARM S R 00±0. Ømm Reservoir H (M)* Weight liter (4 lb) 0mm (.6 ) 8mm (5 ) 9 lb 4 liter (8 lb) 95mm (5.6 ) 8mm (5 ) 6 lb 8 liter (6 lb) 480mm (8.9 ) 48mm (5.8 ) 8 lb * Measurement (M) represents the distance from bottom of pump to center of mounting hole BIJUR DELIMON INTERNATIONAL OPERATORS MANUAL TTN LUBRICATOR 5580 r#9