PICO-tronic Integrated Electronic Control Systems The PICO-tronic generation of control systems is a newly designed unit in an integrated design for the PICO pump. PICO Electrical Pump with integrated PICO-tronic control system The control unit is equipped with an operational databank which saves the following values: Control type Control system version (Hard and software) Serial number Manufacture dates RTC (Real-Time-Clock), date and time can be set for other time zones Operation mode (time, pulse and revolution control) Current values (times, pulses, monitoring results, errors...) Operative offers Pump run time Number of interim lubrications Number of fullness level errors Number of overpressure errors Number of pulse monitoring errors Number of revolution monitoring errors Date and time of last diagnosis Total diagnosis number Error protocol of last 0 errors with entry indicating error type as well as date and time entry. Datum Event protocol of the last 00 setting changes with time and date entries PICO-tronic Integrated Control System with data storage memory MU8500GB Evaluation of individual data can be done either with the system diagnosis unit or on a laptop or PC (cf. description of system diagnosis unit DSG- or BEKA- DiSys diagnosis software). The PICO central lubricating pump has been designed for all control and hardware systems so that it is possible to change between the control systems without difficulty. The following control system types can be selected using the diagnosis software or a system diagnosis unit: A) Time control (setting ex works) B) Pulse control C) Revolution control Depending on usage needs, the control system can be adapted through the selection of the most appropriate program, also on-site, even though the client was already using the control system. Note: System diagnosis connection When switching to another control type the corresponding sticker must be attached to the view window. A sticker set consists of 0 different types of stickers which can also be ordered individually. Order No. for sticker set: 090000 X
Function process: Regardless of the program settings, the or the green signal light (optional) is visible in the cabin for.5 seconds when the ignition is started and indicates that the control unit is function-ready (activation control). The lubrication process begins each time the control unit is first connected. The PICO-tronic integrated electronic control unit has data memory. It is used to record expired time periods. If the ignition is shut off during this cycle or lubrication process, the time is stopped and stored. When the ignition is again turned on, the data are read from the memory and the function process is resumed at the point where it was interrupted. Function-ready display : function-ready:.5 sec. LED green LED red PICO-tronic integrated electronic control system: When the ignition is turned off, an interim lubrication can be done by pressing the push button on the side of the pump motor housing or the pushbutton or the illuminated push button in the cabin. This is also used for the function test. The pump begins immediately with a lubrication cycle which the expired or saved lubrication or cycle time is re-set and begins from the beginning. A grease level control mechanism is standard-integrated into the PICO Electrical Pump. When the minimum grease level is reached, the pump is shut off. Push button to activate interim lubrication Red LED to display Green failures LED for function display Connection plan for connection to external push button: 6 5 orange Interim lubrication Ground terminal Ignition terminal 5 Connection plan for connection to external signal lights: Signal lights: 6 5 green red Light green - + Light red Ground terminal Ignition terminal 5 The illuminated push button light (green) indicates function-readiness of the control system and the current status of a lubrication process. - +
PICO-tronic A) Time control For the time-dependant control of a central lubrication system, the cycle time and the lubrication time can be set. The cycle time is the time period from the beginning of the lubrication process to the beginning of another lubrication. PICO-tronic integrated electronic control (time control): Diagram of a cycle process: Lubrication time Cycle time Setting parameters: Lubrication time: The lubrication time can be set within three time ranges: Dial to set cycle time Dial to set lubricating time Time range I: to6 min. Setting of lubrication time time range I (6 notches each min.) 6 Time range II: to min. Setting of lubrication time time range II (6 notches each min.) Time range III: to sec. Setting of lubrication time time range III (6 notches each sec.)
Parameter setting: Cycle time: The cycle time can be set within three time ranges: Setting time cycle - time range I (6 notches each 0.5 h.) 0,5 Time range I: 0.5 to 8 h Time range II: Time range III: to min. to h Setting time cycle - time range II (6 notches each min.) 8 To set the time remove the blue frame on the pump motor protective housing with a flat screwdriver, unscrew the four recessed head screws and remove the transparent protective cover. The cycle or lubrication time can be set with a flat screwdriver. Setting time cycle - time range III (6 notches each h) If the cover is not properly locked, water can get into the control unit and it can be destroyed. The warranty becomes invalid in this case. All lubrication time ranges can be in any combination with all cycle time ranges. If the time ranges are changed, the appropriate sticker must be attached to the view window on the control unit shell. Setting of continuous lubrication: In order to activate constant lubrication in the time control operating mode for servicing the lubrication time must be set to a high value as the cycle time. The continuous lubrication can be optionally displayed by the alternating red and s in a pulse. Control system technical information: possible operating voltage: 0 to 60 V DC Power load max.: I = 6.0 A Safety (not included in unit): F 6. A (5x0) semi time-lag Outlet for signal light: I = 0, A Temperature range: -5 C to +5 C Protection type: IP 65 Before the electrical connection: Observe the voltage of the pump motor. Display of red and s: Continuous lubrication: Connection plan for connection to control system: 6 5 Ground terminal Ignition terminal 5
PICO-tronic B) Pulse control The lubrication period can be determined with the PICOtronic integrated electronic control unit also using the number of lubrication pulses on the progressive distributor. Here it is necessary to count the number of the piston strokes which the progressive distributor has. If a lubricant is delivered to a progressive distributor, it moves the pistons constantly. A proximity switch is mounted on one of the progressive distributor pistons which sends a signal to the control system at each piston stroke. EP-tronic integrated electronic control unit: Button to activate interim lubrication or to re-set a failure. On the control unit the desired number of the piston strokes set with a switch. When the pump begins to deliver lubrication to the system, the progressive distributor pistons begin to move and the control unit counts the impulses recognized by the proximity switch. If the proximity switch signals remain off for longer than the pre-set monitoring time (standard min. / sec.) after the lubrication process begins, the control unit displays a failure message. The monitoring time can be decreased or increased with the BEKA-DiSys diagnosis software. The green and s in the control unit view window on the pump protective motor housing or the built-in green and red signal light, if present, begin to blink. The failure message can be re-set by pressing the interim lubrication button and the pump starts a new lubrication process. Inductive proximity switch on progressive distributor: Dial to re-set cycle time Dial to re-set pulse number Display of red and : Pulse error on progressive distributor: Proximity switch built into am progressive distributor: Possible operating voltage: 0 to 60 V DC Switch type: PNP-closer Power rating: 00 ma Connection: Mx plug-in Function display: LED yellow Housing material: stainless steel Switch protection type: IP 6 Ambient temperature: -0 C to +85 C Before the electrical connection: Observe the voltage of the pump motor. Connection plan for connecting the proximity switch to the distributor 6 5 6 5 blue Ignition terminal 5 Ground terminal 5
The proximity switch is shipped with a connection cable. The connection to the control unit occurs via the additional plug-type connection on the motor cover cap. The plug in the plug must be removed for this purpose. Connection for connecting pump to onboard network Setting the parameters: Pulse number: Connection for connecting proximity switch to pulse control. The pulse number can be set within three ranges: Setting range I: to 6 pulses Setting range II: to pulses Setting range III: to 8 pulses Cycle time: The cycle time setting is described like the time control setting process. There are also three time ranges to min., 0.5 to 8 h, and to h. These two range types, pulses and cycle time can be in any combination. The cycle time is set like the description for the time control setting. There are also three time ranges: to min., 0.5 to 8 h and to h. These time ranges can be in any combination with the revolution control setting ranges. The instructions for setting the cycle times, like those for time control, should be followed. If the cover is not properly locked, water can get into the control unit and it can be destroyed. The warranty becomes invalid in this case. Setting of pulse number, setting range I: (6 notches each pulse): 6 Setting of pulse number, setting range II: (6 notches each pulse): Setting of pulse number, setting range III: (6 notches each pulse) Note: 8 When changing the time control to pulse control, the sticker in the view window must be changed. 6
PICO-tronic C) Revolution control With the PICO-tronic integrated electronic control unit, it is also possible to determine the lubrication period by the number of revolutions of the pump motor in cases of fluctuations in the revolutions due to low temperatures or high torque A signal is sent to the control unit for each motor revolution and the unit counts the in-coming signals. EP-tronic integrated electronic control: Button to activate interim lubrication or to re-set an error message The pump motor signals remain off longer than the preset monitoring time (standard is 0 sec.) after a lubrication process begins, the control system displays a failure message. The in the view window or an externally fitted signal light (optional) begins to blink. The revolution signal failure can be re-set by pushing on the interim lubrication button and the pump begins a new lubrication process. Dial to set cycle time Dial to set revolution number Connection plan of connection to control unit: 65 Ground terminal Ignition terminal 5 Display of red and Revolution signal error:
Setting parameters: Number of revolutions: The revolution setting is like described for the time control setting. There are also three revolution ranges which can be in any combination with the cycle time setting ranges. The number of pump motor revolutions can be set with three ranges: Setting for the number of pump motor revolutions, Setting range I (6 notches each revolution): Setting range I: to 6 revolutions 6 Setting for number of pump motor revolutions, Setting range II (6 notches each 0 revolutions): 0 Setting range II: 0 to 60 revolutions 60 Setting for number of pump motor revolutions, Setting range III (6 notches each 0 revolutions): Setting range III: 0 to 0 revolutions Cycle time: The cycle time is set like the description for the time control setting. There are also three time ranges: to min., 0.5 to 8 h and to h. These time ranges can be in any combination with the revolution control setting ranges. The instructions for setting the cycle times, like those for time control, should be followed. If the cover is not properly locked, water can get into the control unit and it can be destroyed. The warranty becomes invalid in this case. 0 0 Warning: When re-setting from time control to revolution control, care must be taken that the sticker on the view window on the motor cover cap must be changed. 8
PICO-tronic Overpressure value with micro-switch With the PICO-tronic integrated electronic control unit, the maximum operational pressure of the progressive central lubrication machine can be monitored. A micro-switch is connected to the pump element overpressure valve for this purpose. If an error occurs in the system, e.g. a lubrication point becomes blocked, pressure equalling 50 bar is created in the system. Overpressure valve with micro-switch on the pump element, built into a PICO electrical pump: Micro-switch The overpressure valve activates a micro-switch and sends a signal to the control system. It switches the pump off and the error is indicated by the blinking red LED and continuous or by the externally connected signal lights. Micro-switch technical information: Possible operating voltage: 0 to 60 V DC Power load max. I =.A Contact type: Change-over contact Temperature range: -5 C to +85 C Protection type: IP 6 Connection plan for micro-switch connector: Before the electrical connetion: Observe the voltage of the pump motor. The connection for the connection of the micro-switch to the control system is the same plug connection as described for the grease level control. System pressure monitoring can be done by connected any selected program to the PICO-tronic control unit. 6 5 6 5 blue braun : frei Ground terminal Ignition terminal 5 Display of green and : Overpressure in line system: 9
PICO-tronic Adaptation to usage types Without the system diagnosis unit the following control unit functions can be user: -level switch to set usage type Activation of interim lubrication, also externally Selectable usage requirements: Light 5 % Normal 00 % Heavy duty 5 % The normal setting should be selected for a regular load; the lubrication time and cycle time are executed as set. Medium setting: Cycle time00 % e.g. h The light setting should be used for lighter loads. The cycle time set is increased by 5%, i.e. a cycle time set at h, for example, is increased by 0.5 h to.5 h. Lubrication time Light setting: Cycle time 5 % e.g..5 h The heavy-duty setting should be selected for particularly heavy loads, such as breaking rock. The cycle time set is reduced by 5%, i.e. a cycle time set for h, for example, is reduced by 0.5 h to.5 h. Lubrication time Heavy-duty setting: The usage type can be selected with a switch with three notch settings which are on the vehicle control panel within the first 0 sec. after the ignition is turned on. The ignition must again be turned on and off or interim lubrication must be activated after the usage type has been changed. Cycle time 5 % e.g..5 h Lubrication time Connection plan for connection of three-level switch for adaptation to the usage types: 6 5 grey white max. min. Ground terminal Ignition terminal 5 0
PICO-tronic Starter release relay or collective error message Either a starter release relay or a collective error alarm can be connected to the PICO-tronic integrated electronic control system. The desired connection must be indicated upon ordering or can be selected later with a DSG- system control unit or with diagnosis software. Starter release delay The starter release prevents the vehicle from being left on as long as an error which is displayed by the control system, remains in effect, such as: a pulse error in pulse control, a revolution error in revolution control, a grease level error, overpressure in the line system, GND +6...0V OUT IN The vehicle motor can be restarted only when the error has been eliminated. The start release relay is shipped without a cable and must be fitted on a dry area of the vehicle. Order No.:.900 If the starter release shall be activated, the special version 00 has to be indicated at the order. A collective error alarm can be connected instead of the starter release. An external light or horn will give a constant signal if one of the above-mentioned errors occurs in the system. If an external light is installed in the vehicle cabin, for example, this light would remain illuminated until the error is eliminated. from ignition lock, starter to starter from PIN 5 from PIN LED green : all OK : error If a horn is installed, it will give a constant acoustic signal until the error is eliminated. The light and cable are not included in the shipment. If the collective error alarm shall be activated, the special version 00 has to be indicated at the order. 6 5 6 5 + - Light error ground terminal ignition terminal 5
PICO-tronic Starter release relay or collective error message Two control LED's (green/red) in the view window on the pump motor protection cap indicate the functions; the always indicates an error in the program process. PICO-tonic integrated electronic control system Red LED to indicate errors The LED control functions can also be indicated through the signal lights installed in the vehicle cabin. They must be ordered separately. Function-ready display: Green LED to indicate function Function-ready:.5 sec. Function-ready LED green LED red Lubrication process: During entire lubrication process Active lubrication LED green LED red Pulse error on progressive distributor: Pulse error Grease level too low: Grease level error Overpressure error Revolution error Memory error Test lubrication (continuous lubrication) Overpressure in line system: rote LED grüne LED Revolution error on pump motor: Memory error Test lubrication: Until lubrication container is filled up. 0,5 sec. 0,5 sec.
blue free + - ignition binder5 ground binder either: Starter release relay Collective error alarm Klemme 50 Anlasser und Zündung Over pressure valve with micro-switch Distributor with proximity switch Three-level switch for adaptation to usage types (No...) =Cable-No. at unicoulord cables blue 5 6 orange (No. 6) Interim lubrication button (No. 5) 5 (yellow/green) 6 max. min. gray (No. ) white (No. ) red (No. ) - + Light red + green (No. ) - External signal lights Light green
Order key PICO Electrical Pump Model: 85. X. X. X. X. X. X. XXX Motor voltage Number V V Pump elements PE-0F PE-0FV PE-0F + PE-0FV PE-0F + PE-0FV Starting position 0 +0 without 5 6 X X 0 X X 8 Note: pump elements PE-50 to PE-5 must be ordered separately! Container size Number, kg Control type Number without PICO S-EP motor car PICO-tronic T Trailers and semi-trailers PICO-tronic motor car without 0 PICO S-EP motor car Lubrication Cycle time range time range 0,5 h bis 8 h I min. to 6 min. Z II sec. to sec. T PICO-tronic T for trailers and semi-trailers Lubrication Cycle time range time range 0.5 h to 8 h min. to min. h to h I min. to 6 min. A J II min. to min. B K III sec. to sec. C L PICO-tronic traction machine Lubrication time range Cycle time range 0,5 h to 8 h min. to min. h to h I min. to 6 min. A J II min. to min. B K III sec. to sec. C L Pulse range I pulse to 6 pulses D M II pulses to pulses 5 E N III pulses to 8 pulses 6 F O Revolution number range I revol. to6 revol G P II 0 revol. to 60 revol. 8 H Q III 0 revol to 0 revol. 9 I R Special designs without Number 000 at PICO-tronic with Collective Disturbance Report (Constant Error) with Ignition Release at all other Control Units without 0
Order key PICO-tronic Integrated Control System Model: 85. 900. X. XXXX Type of control Number PICO-tronic tractive machine PICO-tronic tractive machine Lubrication Cycle time range time range 0.5 h to 8 h min. to min. h to h I min. to 6 min. A L II min. to min. B K III sec. to sec. C L Pulse range I pulse to 6 pulses D M II pulses to pulses 5 E N III pulses to 8 pulses 6 F O Revolution range I revol. to 6 revol. G P II 0 revol. to 60 revol. 8 H Q III 0 revol. to 0 revol. 9 I R Special designs Number without 0000 5 X