Operators Manual TTN LubricaTor - Bijur Delimon · 2 BIjur DelIMOn InternatIOnal operators manual ttn luBrICator 35579 r#6 ... control valve for relieving main line ... Power supplied

Operators Manual

TTN LubricaTorInjector Series

35579 r#6

2 BIjur DelIMOn InternatIOnal operators manual ttn luBrICator 35579 r#6

© Copyright Bijur Delimon International 2008.

Bijur Delimon International reserves the right to

update or improve the technical specifications for this

product without prior notice.

BIJur DelImon InternatIonal

(919) 465 4448 lOCal (800) 631 0168 tOll-Free (919) 465 0516 FaX

www.BIjurDelIMOn.COM

2100 Gateway Centre Blvd., Suite 109 Morrisville, nC 27560

Contents

Precautions & Symbols .................................2

Manufacturer’s Statement ...........................2

General ............................................................2

application ......................................................2

TTN Lubricator at a Glance ...........................3

Technical Data ................................................4

iSo Schematic ................................................4

Wiring ...............................................................5

Safety ...............................................................6

installation .....................................................6

Lubricator operation ....................................7

controller operation* ...................................7

controller Modes ...........................................8

Maintenance....................................................9

Troubleshooting .............................................9

How to order ...................................................9

Dimensional Schematics ............................ 11

Notes ............................................................. 12

precautions & symbols

the following symbols, used to identify safety instructions, are defined as follows:

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.

Nelectrical connections made to the neutral conductor are identified with the capital “n”

all safety and/or warning labels affixed to the ttn Injector Series lubricators must be maintained in a completely legible condition. also, any modifications made to the ttn Injector 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 statementthe manufacturer and/or distributor has provided the parts list and assembly diagram in this manual as a reference tool only. neither the manufacturer or distribu-tor 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 replace-ments 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.

Generalttn lubricators are electrically driven piston pumps designed for use with parallel injector systems. For progressive systems refer to Datasheet #35492. these lubricators incorporate an electrical control valve for relieving main line pressure during the interval mode. ttn lubricators are available with an integral programmable controller, low level switch and various reservoir capacities. Operating voltages are either 12 or 24 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 Injector Series lubricator meets all of the operat-ing parameters for Bijur Delimon positive displacement injector centralized lubricat-ing systems. You will need this manual for the safety warnings and precautions, assembly, operating, inspection, mainte-nance 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.

applicationttn 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 lubrica-tion of critical wear points such as bearings, bushings and pins.

3BIjur DelIMOn InternatIOnal operators manual ttn luBrICator 35579 r#6

ttn lubricator at a Glance

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.

ELECTRICAL PLUG (MALE)

RESERVOIR FILLING VALVE

PISTON ELEMENT

ELECTRICAL PLUG (FEMALE)

CONTROLLER (OPTIONAL)

RESERVOIR

SOLENOID VALVE

CHECK VALVE

INTERNAL RELIEF VALVE

LOW LEVEL SWITCH (OPTIONAL)

DC MOTOR

RUNPOWER ALARM

S R


M 2

F

TTN INJECTOR SERIES LUBRICATOR

CONTROLLER

technical Datalubricator

reservoir Capacity 2, 4 and 8 liter (4, 8 and 16 lb)

Grease High Pressure nlGI grade 000-2

low Pressure nlGI grade 000-0

relief Valve setting High Pressure 3600 psi (248 bar)

low Pressure 850 psi (59 bar)

Discharge/min. 16cc (1 cu. in.)

outlets 1 outlet (2 integrated elements)

operating temperature range 1 -13˚F to 122˚F (-25˚C to 50˚C)

operating Voltage 12 or 24 VDC

pump Cam rotary speed 42 rpm

low lubricant level switch 3 amp

electrical Connections 2 Binder rD24

outlet Connection 3 1/4” nPt

Grease Fill Connector Hydraulic quick disconnect

Ip enclosure rating IP-65

Controller (optional)

loading power 70 w

Fuse 12 VDC 8 amp

24 VDC 5 amp

Iso schematic

1 Grease used in system must be pumpable at the temperatures referenced. Contact lubricant manufacturer with specific questions.

2 Electrical Connections Specifications

Number of contacts: 3+PE Wire gauge: AWG 20-14 Cable diameter: 6-9.5mm Screw termination IP Enclosure Rating: IP-67

3 European version is 1/4” BSPP. See notes on page 9.


WiringWith Controller & low level switch (sC)

Without Controller & With low level switch (s)

With Controller & Without low level switch (C)

Without Controller & Without low level switch (n)

LOAD

3

21

12

3

3

2

1

BINDER MALE SOCKET CONNECTOR

INTERNAL FACTORY SUPPLIED WIRING

EXTERNAL CUSTOMER SUPPLIED WIRING

BINDER FEMALE SOCKET CONNECTOR

FACTORY SUPPLIED FEMALE BINDER PLUG CONNECTOR

1—RED 2—YELLOW 3—BLUE —BLACK 1—RED 2—BLUE 3—YELLOW —BLACK

2

3MECHANICAL CONTACT SWITCH 2 WIRES

EXTERNAL CYCLE COUNT OR PRESSURE SWITCH

POWER SUPPLY

LED

1

3

2

EXTERNAL ALARM INDICATOR LIGHT (LED) [OR RELAY 200 mA MAX]

1

2

3

FACTORY SUPPLIED MALE PLUG CONNECTOR

3

1

2PROXIMITY SWITCH3 WIRES |NPN TYPE|

1—BROWN 2—BLUE 3—BLACK

3

21



EXTERNAL CUSTOMER SUPPLIED WIRINGSHOWN WITH SMDC (MOBILE) CONTROLLER

1—RED —BLACK

NO BINDER FEMALE SOCKET CONNECTOR PRESENT ON PUMP

MOTOR ENCLOSURE

12

3

NOTE: REFER TO SMDC INSTRUCTIONS FOR ACCESSORY COMPONENT WIRING SPECIFICATIONS

FACTORY SUPPLIED FEMALE PLUG CONNECTOR

BIJUR DELIMON

SM

DC CONTROLLER

33346M

EXTERNAL CUSTOMER SUPPLIED WIRINGSHOWN WITHOUT SMDC (MOBILE) CONTROLLER

1 2

3 4

5 6

7 8

POWER SUPPLY

12

3

1

3


3

21

12

3



EXTERNAL CUSTOMER SUPPLIED WIRINGSHOWN WITH SMDC (MOBILE) CONTROLLER

NOTE: REFER TO SMDC INSTRUCTIONS FOR ACCESSORY COMPONENT WIRING SPECIFICATIONS

FACTORY SUPPLIED FEMALE PLUG CONNECTOR

BIJUR DELIMON

SM

DC CONTROLLER

33346M

EXTERNAL CUSTOMER SUPPLIED WIRINGSHOWN WITHOUT SMDC (MOBILE) CONTROLLER

NO BINDER FEMALE SOCKET CONNECTOR PRESENT ON PUMP

MOTOR ENCLOSURE

1 2

3 4

5 6

7 8

1—RED 2—BLUE 3—BLACK —BLACK

2

INTERNAL LOW LEVEL MECHANICAL MOMENTARY CONTACT SWITCH2 WIRES

POWER SUPPLY

12

3

1

3

CONNECTIONS TO LOW LEVEL PROXIMITY SWITCH 3 WIRES |NPN TYPE|LOAD TO BE LED OR RELAY 200 mA MAX

CONNECTIONS TO LOW LEVEL MECHANICAL SWITCH |LOAD 3A MAX|



1

3

LOAD2LOAD

3

21

POWER SUPPLY

12

3 LED

1

3

2

2

3

3

1

2

3

2

1

1

2

3



EXTERNAL CUSTOMER SUPPLIED WIRING

BINDER FEMALE SOCKET CONNECTOR

MECHANICAL CONTACT SWITCH 2 WIRES

EXTERNAL CYCLE COUNT OR PRESSURE SWITCH

PROXIMITY SWITCH3 WIRES |NPN TYPE|

EXTERNAL ALARM INDICATOR LIGHT (LED) [OR RELAY 200 mA MAX]


FACTORY SUPPLIED MALE PLUG CONNECTOR

1—RED 2—YELLOW 3—BLUE —BLACK 1—RED 2—BLUE 3—YELLOW —BLACK


LOAD


Initial Fill Condition

exhausting air

reservoir Fill Complete

1 Grease

2 air

3 Bellows Vent Hole

safetythis 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

mounting

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 tempo-rarily removed during the installation of the ttn lubricator.

locate the ttn lubricator away from 1. heat sources.

Provide access to the lubricator 2. for means of filling, cleaning and visual inspection.

always adhere to installation instruc-3. tions 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.

use drilling templates to locate and 4. drill mounting holes. Mounting plates and templates are available for this product. when possible use existing mounting holes or studs.

lubrication lines and electrical cable 5. 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 tubing and 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.

1

2

3

1

2

1

1

2

3

1

2

1

1

2

3

1

2

1


lubricator operationPower supplied to a motor with gear box drives a precision eccentric cam which engages with two spring loaded piston elements. this action creates a suction and pressure stroke of the elements, thereby displacing fixed volumes of lubricant to a centralized outlet on the pump. lubricant is displaced through main line tubing or hose to a network of manifolds and injectors. after proper system pressure is obtained, the lubricator and internal control valve are de-energized. this allows for the venting of main line pressure and the recharging of all injectors. the lubricator is protected by an internal relief valve.

Controller operation*

Controller status leDs

red steady lubrication cycle

Yellow Flashing alarm

Green steady Power supply on

none lit no input power to controller

Keys Description

s Select

r Enter and reset

Step selection

adjustment

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 (1-4). See page 7 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 3 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.


Controller modes

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 1 to 9999 minutes. a four second run delay following a pressure switch closure assures adequate pressure downstream from the pump.

Cycle Control mode (d 3)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 prede-termined number of cycle counts (1-999). Once the preset number of counts is obtained the controller will stop the pump and revert back to the idle time setting (1-9999 minutes).

SET-UP MODE “S”+”R”

CONTROL MODE 1~41 2 3 4

RUN TIME1~999(S)

MONITORTIME1~999(S)

IDLE TIME 1~9999(M)

RETURN TO SET UP MODE

RUN

CYCLE COUNT1~999(C)

PRESSURE COUNT1~99(C)

PULSE ON1~99(S)

PULSE OFF1~99(S)

REVIEW ”S”

“S”

“S” “S”

“S” “S” “S”

“S”

“S”

“S”

“S”

“S”“R”

X

X X X X X X X X X X X

X X

X XX X X X

If the desired number of cycle counts is not obtained within five minutes of run time (non-adjustable), an alarm signal will be displayed (yellow leD on and 000 appears on the digital readout). Possible causes for this type of alarm could be pump malfunction, divider valve malfunc-tion, 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.

timer Control mode (d 1)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 2)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 1.5 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).

* For lubricators fitted with low level switch


troubleshooting

symptoms possible Cause remedy

no power to lubricator Blown fuse replace fuse and check load

loose electrical connection repair or replace wire

Defective circuit board replace circuit board

Incorrect wiring Check polarity

no grease delivery reservoir low on grease Fill or top off reservoir

Hardened or separated grease Clean and replace with approved grease

Defective pump element Service or replace element

air pockets in grease refill and purge air

Defective control valve replace solenoid coil

Defective motor replace motor

Defective level switch replace level switch

Insufficient pressure Faulty relief valve replace relief valve

air pockets in grease refill and purge air

worn or defective pump elements repair or replace elements

Faulty check valve replace check valve

loose fittings or broken tubing repair or replace

How to order

name Voltage reservoir Capacity

options part # part #

850 psi 1 3600 psi

ttn Injector lubricator2

12 VDC 2 liter (4 lb) low level switch ttn2B2S123 ttn2B1S123

low level switch & controller ttn2B2SC12 ttn2B1SC12

4 liter (8 lb) low level switch ttn4B2S123 ttn4B1S123


24 VDC 2 liter (4 lb) low level switch ttn2B2S243 ttn2B1S243






1 Fluid grease systems only.2 Other configurations available upon request. Contact Bijur Delimon for details. 3 Requires remote controller (See Datasheet #46911: SMDC Controller).

accessoriesDescription part # part #

850 psi 3600 psi

Mounting plate (straight) 35455 35455

Mounting plate (90°) 35456 35456

adjustable pressure switch ttn lP (factory set at 600 psi) 35517-1 ---

adjustable pressure switch (factory set at 2000 psi) --- 35517-2

Pressure gauge (3000 psi, 1/4” nPt, CBM) u902DB ---

Pressure gauge (5000 psi, 1/4” nPt, CBM) --- u902FB

Mating fill connector uX43521 uX43521

maintenancettn lubricators require limited mainte-nance. 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 Injector lubricator, 12 VDC, 2 liter (4 lb), low level switch, 3600 psi, Part #ttn2B1S12.

North American Element Code #’s: B1: PDI, 1 element, 3600 psi, 1/4” NPT threads B2: PDI, 1 element, 850 psi, 1/4” NPT threads

European Element Code #’s: D1: PDI, 1 element, 3600 psi, 1/4” BSPP threads D2: PDI, 1 element, 850 psi, 1/4” BSPP threads


1

14

2

4

3

11

9

10

8

15

12

13

16

5

6 RUNPOWER ALARM

S R7

21

See specific Piston Element parts on page 11.

service parts: ttn lubricator

Item # Description part # Qty.

1 O-ring 22100-38 3

2 Bearing 25101-2 1

3 Fill connector 52043 1

4 Shaft seal 22178-6 1

5 electrical plug: signal (male) 52041-1 1

6 electrical plug: power (female) 52040-1 1

7 Controller (24 VDC) 51896 1

Controller (12 VDC) 51896-1 1

8 reservoir cover: 2 liter (4 lb) 56683-1 1

reservoir cover: 4 liter (8 lb) 56683-2 1

reservoir cover: 8 liter (16 lb) 56683-4 1

9 relief valve (850 psi) 22474-5 1

relief valve (3600 psi) 22474 1


10 Check valve 52036 1

11 low level switch (mech.) 41834-2 1

low level switch (electric) 49653-27 1

12 washer seal 52038 1

13 Solenoid valve (12 VDC) 49641-9 1

Solenoid valve (24 VDC) 49641-8 1

14 Motor (24 VDC) 22450-4 1

Motor (12 VDC) 22450-5 1

15 Bottom cover 49968-1 1

16 Copper seal 25589-7 1

--- Fuse: 5 amp (24 VDC) 31076-2 1

Fuse: 8 amp (12 VDC) 31076-4 1


service parts: piston element


17 Copper seal 25589-5 2

18 Outlet adapter 22491-9 1

19 Swivel connector 52026-2 1

20 Swivel connector 52026-3 1

Center piston element (part #52025-2)

left piston element (part #52025-3)

reservoir sub-assemblies


21 2 liter (4 lb) Sub-assembly kit 56471 1

4 liter (8 lb) Sub-assembly kit 56472 1

8 liter (16 lb) Sub-assembly kit 56474 1

* 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 10 (Item #21) 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.

19

18

17

18

20

17

Center Piston Element 1/4” NPT threads: Part #52025-2 1/4” BSPP threads: Part #52025-6

Left Piston Element 1/4” NPT threads: Part #52025-3 1/4” BSPP threads: Part #52025-7


Dimensional schematics

reservoir H (m)* Weight

2 liter (4 lb) 320mm (12.6”) 128mm (5”) 29 lb

4 liter (8 lb) 395mm (15.6”) 128mm (5”) 36 lb

8 liter (16 lb) 480mm (18.9”) 148mm (5.8”) 38 lb

* Measurement (M) represents the distance from bottom of pump to center of mounting hole

1/4” NPTOUTLET

OPTIONALOUTLET

H

RUNPOWER ALARM

MAX FILL

MIN FILL

S R

314

200±0.3

(M)

Ø11mm

Measurements shown in millimeters.


notes

Documents

Operators Manual TTN LubricaTor - Bijur Delimon · 2 BIjur DelIMOn InternatIOnal operators manual ttn luBrICator 35579 r#6 ... control valve for relieving main line ... Power supplied