DYNA-POWER LUBRICATION€¦ · kPa 6 16 19 Standard Station Packages Model: DP25(E)-2100 - Standard System w/Bulk-Fill Model: DP25(E)-2101 - Standard System w/Bulk-Fill and Timer

A division ofDyna-Power Engineers,Inc.15330 Greenwood AveSouth Holland, IL 60473

JUNE 2003

DP 25 CENTRAL STATIONGrizzly

DYNA-POWER LUBRICATIONTECHNICAL BULLETIN D-01-07-02

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Model: DP25-2000Serial Number: 0012105

DYNA-POWER LUBRICATIONA Div. of Dyna-Power Engineers,Inc.

12809 South Homan Ave.Blue Island IL 60406

ph: (708)389-7200 fax: (708)389-9619

FOR CUSTOMER SERVICE & APPLICATION HELP:

Dyna-Power Engineers15330 Greenwood Ave.

South Holland, IL 60473

ph: (708) 333-9300 fax: (708) 333-7092

TABLE OF CONTENTS:

I. Overview / General Page No.

A. Ordering Information 1

B. Specifications 1

C. Operation 2

D. Overall Dimensions 2

II. Central Station Packages

A. DP25(E)-2000 3

B. DP25(E)-2010 3

C. DP25(E)-2001 4

D. DP25(E)-2011 4

E. DP25(E)-2100 5

F. DP25(E)-2101 5

G. DP25(E)-2111 6

III. Basic Installation 6-7

IV. Component Detail

A. Reservoir 8

B. Pump 9-11

C. Gear Reducer 11

D. Mounting Base 12

E. Hydraulic Reversing Valve 13-14

F. Electrical Reversing Valve 15

G. Timer 16-17

H. Mechanical Shut-Off 18

1DP 25 CENTRAL STATION

Overview:

The Grizzly central station is a perfect mid-size automatic lubricating station for heavyindustrial applications. The Grizzly is bestapplied in single or dual systems that donot exceed 100’ header length or exceed150 lubrication points. The following bulletincontains information pertaining to parts,dimensional data, and ordering informationfor the main system only. For information onsecondary parts and accessories, pleasesee their respective technical bulletins.

Ordering Information

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ph: (708)389-7200 fax: (708)389-9619

General Specifications:

Pump Description:Type: Motor driven, twin piston (uses

20:1 external gear reducer)Capacity per Stroke: .06 cu.in.Capacity per Minute: 5.13 cu.in.Discharge Pressure: 3000 psi.

Reservoir Description:Grease: 50 lbs. capacityMaterial: Steel

Motor Description:1/3 h.p. @ 1750 rpm, 230/460VAC-60HZ-3 phase. (Single phase avail-able and DC motors available)

Reversing Valve:DRV32-SL (std), DRV31-SL(pre-1999),RVE1-DS1 (pre-2000), RVE2-DS1 (std)

Station Packages Part Number

Standard System- Includes reversing valve, motor, andlow level switch in addition to reservoir, pump, gear reducer,cover, bases, and requisite piping and fittings

Std.System w/Motor Starter- Includes above standardsystem with main fuse disconnect switch, motor starter withoverload relay, control transformer 230/460VAC (primary),115VAC (secondary) in a NEMA 12 enclosure.

Std.System w/Timer- Includes above standard system witha timer and indicator lights which display:“Timing”,“Pumping”,and “Fault. Also included is a reset/manual push button.Std.System w/Timer and Motor Starter- Includes abovestandard system, motor starter package, and timer package.(see above packages for descriptions.)

Std.System w/Bulk-Fill- Includes above standard systemwith high-force solenoid shut-off valve (SVE2-SS1), mech-anical shut-off valve, high-low level switch, pre-installed highpressure hoses, and terminal box w/ seal-in relay (115VAC).

Std.System Complete- Includes above standard system withmotor starter package, timer package, and bulk-fill package.(see above packages for descriptions).

DP25-2000 DP25E-2000 DP25S-2000

DP25-2010 DP25E-2010 DP25S-2010

DP25-2001 DP25E-2001 DP25S-2001

DP25-2011 DP25E-2011 DP25S-2011

DP25-2100 DP25E-2100 DP25S-2100

Std.System w/Bulk-Fill and Timer - Includes abovestandard system with the above bulk-fill and timer packages. DP25-2101 DP25E-2101 DP25S-2101

DP25-2111 DP25E-2111 DP25S-2111

Uses a hydraulicallyoperated reversingvalve.

Uses an electricallyoperated reversingvalve.

Does not use a rev-ersing valve.(Forsinlge line systems)

DYNA-POWER LUBRICATION SOUTH HOLLAND IL PH:708.333.9300 FAX:708.333.7092

2 DP 25 CENTRAL STATION

Overall Dimensions

*All dimensions are in inches unless indicated otherwise.

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ph: (708)389-7200 fax: (708)389-9619

35.7

549

.25

max

26.77

19.693.54

12.6

0

14.1

7

The Grizzly pumping station consists of a twin piston pump, 20:1 gear reducer, 50lbs. steel reser-voir with follower plate and indicator stem, reversing valve, and 1/3 h.p. motor in a NEMA 56 TEFCframe.

The standard system begins when power is applied to the motor which, in turn, activates the pump.In a dual line system, one line is pressurized by the pump while the second line relieves lubricantback to the reservoir. During subsequent lubrication cycles, the pressurized line is relieved andthe relief line is pressurized. This alternate action is controlled by the reversing valve. The rev-ersing valve, via a switch, sends the cycle information to the control (if applicable) which can be usedto set the cycle time. And it is the time set for the lubrication cycle, together with the measuringvalve settings that will determine the amount of lubricant that goes to each bearing.

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Supply Line

ReliefLineMotor

GearReducer

Pump

Reservoir

1500

2000

2500

3000

1000

500

Discharge Lines 1 & 2

PressureSetting

CycleSwitch

Operation


LLLL LL


* The following parts are not used for (E) electric reversing valve packages.

1 1 P25-1200-1 Reservoir ASM

2 1 P25-1181-1 Gear Reducer

3 1 DP25-CG Coulping Guard

4 1 DP25-C100 Coupling

5 1 0620-3534 Motor

6 1 P25-JB Juntion Box

7 1 DP25-143-1 Switch Cam

8 1 LSD4C2200 Low Level Switch

9 1 P25-1601-100 Pump ASM

10 1 P25-1650-1 Adapter Block

11* 1 D902D Pressure Gauge

12* 1 MG2-00-1002-1 Adapter

13* 1 DRV32-SL Reversing Valve

14 1 P25-2300-1 Mounting Base

15 3 P080-6-8 Elbow

16 1 P115-6-8 Fitting

17 1 P25-2350-1 Mounting Frame

18 1 CC02-1001-1 M.S./D.S. Cabinet

Item Qty. Part No. Description

Standard Station Packages

Model: DP25(E)-2000 - Standard System

er: 0012105

LUBRICATION-Power Engineers,Inc.

South Homan Ave.Blue Island IL 60406

fax: (708)389-9619

psikPa

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Model: DP25(E)-2010 - Standard System w/Motor Starter / Disconnect Switch


Includes main fuse disconnect switch, motor starter with overload relay,control transformer (230/460VAC-primary, 115VAC-secondary) in a NEMA12 enclosure.





5 1 0620-3534 Motor

6 1 P25-JB Juntion Box



9 1 P25-1601-100 Pump ASM



12* 1 MG2-00-1002-1 Adapter



15 3 P080-6-8 Elbow

16 1 P115-6-8 Fitting



LLLL


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PUMPING FAULT

POWER ON

TIMING

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POWER ON

MANUALRESET

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Model: DP25(E)-2001 - Standard System w/TimerTimer indicator lights display “Timing”, Pumping”, and “Fault”. Also includedis a manual/reset button.

Model: DP25(E)-2011 - Standard System w/Timer andMotor Starter / Disconnect Switch





5 1 0620-3534 Motor

6 1 -- Not Used



9 1 P25-1601-100 Pump ASM



12* 1 MG2-00-1002-1 Adapter



15 3 P080-6-8 Elbow

16 1 P115-6-8 Fitting


18 1 CC1-102-01T Timer






5 1 0620-3534 Motor

6 1 -- Not Used



9 1 P25-1601-100 Pump ASM



12* 1 MG2-00-1002-1 Adapter



15 3 P080-6-8 Elbow

16 1 P115-6-8 Fitting


18 1 CC1-103-01T Timer




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Model: DP25(E)-2100 - Standard System w/Bulk-Fill

Model: DP25(E)-2101 - Standard System w/Bulk-Filland Timer



er: 0012105



fax: (708)389-9619

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MANUALRESET

PUMPING FAULT

POWER ON

TIMING

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5 1 0620-3534 Motor

6 1 CC1-101-01B Junction Box



9 1 P25-1601-100 Pump ASM



12* 1 MG2-00-1002-1 Adapter



15 3 P080-6-8 Elbow

16 1 P115-6-8 Fitting

17 1 DPLC7937-AC Mech’l Shut-Off

18 1 MG-00-9001-1 Hose Assembly

19 1 LSD4C1203 Switch






5 1 0620-3534 Motor

6 1 -- Not Used



9 1 P25-1601-100 Pump ASM



12* 1 MG2-00-1002-1 Adapter



15 3 P080-6-8 Elbow

16 1 P115-6-8 Fitting




20 1 CC1-102-01T Timer








5 1 0620-3534 Motor

6 1 -- Not Used



9 1 P25-1601-100 Pump ASM



12* 1 MG2-00-1002-1 Adapter



15 3 P080-6-8 Elbow

16 1 P115-6-8 Fitting




20 1 CC1-103-01T Timer


er: 0012105



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TIMING PUMPING FAULT

POWER ON

MANUALRESET

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Model: DP25(E)-2111 - Standard System Complete

Consists of the standard system, motor starter/disconnect switch package, timerpackage and bulk-fill package.

Basic Installation

The central station should be securely mounted on the floor or stable platform.See page 7 for mounting dimenions.

In hydraulically reversed stations, connect discharge lines 1 & 2 using 3/8”compression fittings. Then, using an appropriately sized screw driver, turnthe air bleed screw 1/4 turn counter-clockwise. After all the trapped air hasescaped, tighten the air bleed screw--turing the screw 1/4 clockwise. Nowwire the limit switch to the proper control. Then, using an appropriatelysized wrench, loosen the nut just below the pressure adjustment. Turn thepressure adjustment to either raise or lower the pressure. Turning the press-ure adjustment clockwise increases the pressure and turning it counter-clowise decreases the pressure. After pressure has been adjusted, tightenthe lock nut. See Fig.A. DO NOT ADJUST WHILE SYSTEM IS UNDERPRESSURE!

Pre-fill header and supply lines.

A

B

Fig.B

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LIMIT SWITCH(LSD4C1203)

DISCHARGE PORT(3/8”N.P.T.)

PRESSURE ADJUSTMENT

Air BleedScrew

Fig.A

Electrical connection to the motor may be necessary depending on the model.

In electrically reversed stations, connect discharge lines 1 & 2 using 3/8”compression fittings to ports A and B. See fig.B. Wire the reversing valveto proper control, noting the wiring diagram found on page 15.



Standard Station PackagesModel: (E) Electrical Reversing Valve

Systems with electrical reversing valves do not rely on systempressure to alternate between discharge lines directly. Pressureswitches should be purchased separately and wired to the maincontrol / timer.

PLC or remote operation is required.

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Discharge Line#1

1

2

Discharge Line#2

3

Supply Line Relief Line

3

3

3

1 1 RVE2-115 Reversing Valve

2 1 VE!-63 Subplate

3 4 P115-6-8 Fitting




Reservoir Detail

1

2

3

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9 10

12

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31

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Item Qty Part No. Description

1 1 DP25-140-1 Body

2 1 DP25-141-1 Cover

3 1 DP25-950-A Oil Seal

4 1 DG1401 Plug

5 2 DP25-906-A Screw

6 1 DP-142-1 Follower Rod


8 2 DP25-907-A Set Screw

9 1 DP25-909-A Vent Screw

10 1 DP25-951 Ball

11 - - Not Used

12 2 DP25-961-A Hex Nut

13 1 DP25-142-A Follower Plate

14 6 DP25-952-A Bolt

15 1 DP25-143-A Packing

16 6 DG3020 Lock Washer

17 6 DP25-962-A Nut

18 1 DP25-144-A Gasket

19 6 DP25-963-A Bolt

20 6 DP25-970-A Lock Washer

21 3 DG3022 Lock Washer

22 3 DP25-963-A Hex Nut

23 1 LSD4C2200 Limit Switch

24 1 DP25-145-A Plate

25 - - Not Used

26 - - Not Used

27 - - Not Used

28 - - Not Used

29 - - Not Used

30 3 DG2102 Bolt

31 1 MF-2910-1 Elbow



Pump Detail / Parts Breakdown

22

28

1

2345678910

Check AssemblyP/N: MP-5001-A

12

11

15 16 17 18 19 2120

14

13

29

(Part Number: P25-1601-100)

The P25-1601-100 is a twin piston pump.The motor, coupled to the crank shaftrotates the eccenter, which in turn, alternativelymoves the pistons in and out of their respectivecylinders. This action draws the lubricant fromthe reservoir and pushes it through the thedischarge ports. Back flow of lubricrant isprevented by way of a check valve assemblylocated in front of the cylinder.



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26

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Pump Detail / Parts Breakdown

18 1 DP25-946-A Washer

19 1 DP25-169-A Filter Screen


21 1 DP25-155-A Plug

22 4 DG1501 Plug

23 1 DP25-984-A Set Screw

24 1 DP25-156-A Eccenter

25 1 DP25-954-A Gasket

26 1 DP25-961-A Plug


28 1 DP25-157-A Housing

29 1 DP25-158-A Yoke

1 2 DP25-203-A Piston

2 2 DP25-440-A O-Ring

3 2 DP25-441-A O-Ring

4 2 DP25-125-A Cylinder

5-10 2 MP-5001-A Check ASM

11 2 DP25-930-A Cover

12 4 DP25-944-A Screw


14 2 DP25-960-A Shim

15 1 QHP4 Coupling (Check)

16 1 P010-4 Nipple

17 1 MP1102-A Adapter

Item Qty. Part No. Item Qty. Part No.Description Description



Pump Dimensional Detail

5.75

4.570.59

160 mm

150mm4- 12mm

154m

m

79m

m

Gear Reducer Dimensional Detail - (P/N:P25-1181-1)

163.5mm

88mm

0.9840.709

12 m

m

13.5

mm

4 mm

H-L8.3

5

4.21

4.76

3.27 0.71

base

C shaft



Mounting Base(Part Number: P25-2300-1)

1.2

2.0

4 - 1.0

1.2

2- M6 Tap 4- 0.59

0.8

4.57

12.6

19.69

26.8

3.5

3.27

2.36

1.0

4- 0.43



Parts DescriptionDRV32 - Hydraulic Reversing Valve

3.93

7.08

3.14

7.87

1.83

4.71

4.561.49

1.69

0.4

0.4

0.4

9/32 dia. 8 places

5.74

.98

1.1713 gage

Mounting bracket (p/n: RV0482)

43

27 28

37 39

35

3.54

3.23

2.75

1.37

1.69 1.57

5.74

7.95

1.65.55

7.36

302936

4544

48 49

2.87

7.087.87

.39

2.16

.98

.70 3

.54

2.95

-3.3

8

47

46

34

31

32

2.28

1.61

3.14.39

3.93

.15


1 1 RV0480 Body 26 9 DG3003 Washer

2 1 RV0467 Spring Holder 27 6 DG2001 Hex Screw

3 1 RV0474 Adj. Screw 28 6 DG3004 Lock Washer

4 1 RV0475 Lock Nut 29 4 DG2002 Hex Screw

5 1 RV0473 Spring 30 4 DG3005 Lock Washer

6 1 RV0476 Spring Shoe 31 1 RV0481 Cover Plate

7 1 RV0477 Link 32 1 DG4005 O-Ring

8 1 RV0478 Side Block 33 1 LSD4C 1203 Limit Switch

9 2 RV0472 Pilot Piston 34 2 DG2003 Screw

10 2 RV0471 Pilot Piston Plug 35 2 DG9004 Hex Nut

11 2 DG3001 Washer 36 1 RV0200 Bracket

12 1 DG4001 O-Ring 37 1 RV800124 Air Vent Screw

13 1 DG4002 O-Ring 38 1 RV800263 Hex Plug

14 1 RV0470 Main Piston 39 1 DG9005 Steel Ball

15 1 RV800264 Packing Gland 40 1 RV0479 Slipper Plate

16 2 DG3002 Washer 41 3 DG1002 Plug

17 1 RV800265 Screw 42 3 DG3006 Washer

18 1 RV800251 Switch Cam Rod 43 1 D902D Pressure Gauge

19 1 DG9001 Switch Cam 44 1 RV0482 Bracket

20 1 DG4003 O-Ring 45 4 DG2004 Bolt

21 1 DG4004 Back-up Ring 46 4 DG3006 Washer

22 1 DG9002 Spring Pin 47 4 DG9007 Hex Nut

23 1 DG9003 Roll Pin 48 4 DG2001 Hex Screw

24 ---- ----------- Not Used 49 4 DG3004 Lock Washer

25 9 DG1001 Plug

Item Qty Part No. Description Item Qty. Part No. Description


Parts DescriptionDRV32 - Hydraulic Reversing Valve

3

4

2

5

6 7

8

9

11

10

16

15

17

19

18

222120

2342411440

38

18

1 26 25 13 12



4.71 4.71

9.43

2.76

4.29

3.60

2.68

1.42

RVE2-115

2 5/83/8

3/8

4 1/8

5/84 PLACES 13/32

4 PLACES

4 1/2

1 15/16

A

11/16

1/2” NPT

7/81 1/2

P

T

31 1/2

7/8

1/2” NPT

B

1 15/16

11/16

1 1/2

VE1-63

Solenoid Voltage

Coil Model

Applied Voltage

Frequency (HZ)

Starting Current (A)

Holding Current (A)

Holding Power (W)

Permissible VoltageRange (V)

RVE2Model

115 V-AC

D-3BH-C1/C3

AC110 AC120

60 60

4.6 5.0

0.86 1.0

34 42

80 - 120

ELECTRICAL SPECIFICATIONS

Parts DescriptionRVE2 - Electric Reversing Valve

NOTE:

AC Coils are rated for both 50/60 Hz(rewiring not required).

Do NOT supply electrical power tothe AC coils unless the coil is mountedon the valve.

Do NOT exceed voltage specificationsshown here.

Electrical power should be maintainedon non-detented valves. Detent onlymaintains start-up position of the valve.

!

!

SO

L ASO

L B

Indicating Light

Ground Terminal Solenoid B Terminal

Solenoid A Terminal

Ground TerminalCommon Terminal

Common Jumper

Wiring Diagram



CHGPRE

MSG

STAT OPT

CLR ENT

LUBETIME 0015FAULTIME 0008# CYCLES 0001

Move RightMessage

Change Preset

Move Left

IncreaseDecrease

Enter

Data Field

Text Field

Operator Interface Buttons

Change Preset: Pressing thisbutton will bring up the “PresetScreen”.

Message: Pressing this button willreturn the user back to the messagescreen that is currently active.

Move Right /Left: These buttonsmove the cursor either right or leftin the data field.

Increase /Decrease: These buttonsincrease or decrease the values inthe data fields on the “ChangePreset” screen. Each push of thebutton will either increase or decreasethe value by one. Larger changes invalues may made faster by use ofthe left / right arrow keys.

Enter: Press this button to move thecursor from the text field over to thedata field and back.

During normal operation, the operatorinterface will display the power-up ortiming screen. Presets can not bechanged while the operator interfaceis in this mode.

CHGPRE

MSG

STAT OPT

CLR ENT

POWER ONLUBETIMEFAULTIMETOTAL CYCLES

0015 MIN0008 MIN 0002

CHGPRE

MSG

STAT OPT

CLR ENT

TIMINGLUBETIMEELPSTIMETOTAL CYCLES

0015 MIN0008 MIN 0002

CHGPRE

MSG

STAT OPT

CLR ENT

LUBETIME 0015FAULTIME 0008# CYCLES 0001

Parts DescriptionLube Guardian

Operational Message Screens

Preset InstructionsPower-up Default Screen Timing Screen Preset Screen

CHGPRE

To Change Presets:

Press the key to go to thethe ‘Change Preset’ screen. (Inorder to change a particular setting,the blinking cursor must be alignedwitt the desired preset menu line).

1

MANUALRESET

PUMPING FAULT

POWER ON

TIMING

CHGPRE

MSG

STAT OPT

CLR ENT

CHGPRE

MSG

STAT OPT

CLR ENT

POWER ONLUBETIMEFAULTIMETOTAL CYCLES

0015 MIN0008 MIN 0002

Power-up Message Screen

This default screen is displayedwhen the system is powered up.The ‘Lube Time’, ‘Faultime’, and‘Total Cycles’ is displayed but thethe timer is not activated unlessthe ‘Auto’ contact is closed orjumpered.

CHGPRE

MSG

STAT OPT

CLR ENT

TIMINGLUBETIMEELPSTIMETOTAL CYCLES

0015 MIN0008 MIN 0002

Timing Message Screen

This screen will display if the ‘Auto’contact is closed or jumpered. Thepreset ‘Lube Time’, the ‘ElapsedTime’, and the preset number of‘Cycles’ are indicated.

CHGPRE

MSG

STAT OPT

CLR ENT

PUMP RUNNINGFAULTIME0001 MIN# CYCLES CMP0001

Pumping Message Screen

This screen will display when the‘Lube Time’ has expired and thepump is activated. The ‘Faultime’indicates the amount of fault timethat has elapsed. ‘# Cycles Cmpl’indicates the number of cycles thesystem has completed during thecurrent lubrication cycle.

2

3

4

Press the key to scroll the menuup. Press this key until the cursor is atthe menu line to be changed.

Press the key. (The cursor is nowin the data field).

Press the or the key to ad-just the numeric preset value up or down.

Once all the desired presets have beenmade, return to the default message screen.Instructions follow.

ENT

To return to the default meassage screenfirst press the key to return the cursorback to the left field and then

Press the key. You should now beback at the default message screen.

5

6

ENT

MSG



Parts DescriptionLube Guardian contd.

Preset Instructions Contd.

Terms:

‘Lubetime’ is the interval between lubrication cycles.

‘Faultime’ is the time allowed for the system to rev-erse before it faults.

‘#Cycles’ sets the number of cycles of the reversingvalve during a pumping operation.

Fault Screens


Time-Out Fault Screen

CHGPRE

MSG

STAT OPT

CLR ENT

FAULT TIMERTIME-OUT

CHECK FOR LEAKIN LINE #1 OR #2

Bulk Fill Alarm Screen

CHGPRE

MSG

STAT OPT

CLR ENT

ALARMBULK FILL FAULT

Motor Overload Alarm Screen

CHGPRE

MSG

STAT OPT

CLR ENT

MOTOROVERLOAD

TRIP

This screen will display when thelube cycle (from one reversal to thenext) was not completed within theset fault time. Check for the follow-ing: - Broken pipes or leaking meas- uring valves.

- Reservoir level.

- The motor and motor overload.

To reset the system, press the “Man-ual / Reset” push button.

This screen will display when thelow level switch on the grease res-ervoir does not change state (fromthe N.C. position at low level to theN.O. position after the bulk fill beginsrefilling the reservoir).

Check the bulk fill air pump and thebulk fill solenoid valve.


This screen will display when a motoroverload occurs and the overload relaytrips. Check for the following:

- Binding in the pump and gear reducer.

- Motor windings for shorts (single phasing)


Motor Starter Failure Alarm

CHGPRE

MSG

STAT OPT

CLR ENT

MOTOR STARTERDID NOT PULL INCHECK STARTER

COIL

This screen will display when themotor starter does not pull in andthe feedback contact does not close.Check for the following:

- PLC output Y06 and PLC input X02.

- Motor starter coil for burn out.


DPLC7937-AC - Mechanical Shut-Off Valve

Parts Description


4 1/2”

The mechanical shut-off valve is intended to be used as anemergency shut-off of the grease bulk fill in the event thatthe bulk-fill solenoid fails to shut-off the grease flow into thereservoir.

An optional microswitch (not shown) can be used for faultindication.


Documents

DYNA-POWER LUBRICATION€¦ · kPa 6 16 19 Standard Station Packages Model: DP25(E)-2100 - Standard System w/Bulk-Fill Model: DP25(E)-2101 - Standard System w/Bulk-Fill and Timer