pumping center sg-2102-eco - lubriflexsafegrease 2 sg-2102-eco 2102eco2fen.doc 19.05.2003 rev. 2f 2...

SAFEGREASE 2 SG-2102-ECO

2102ECO2FEN.doc 19.05.2003 Rev. 2F

PUMPING CENTER SG-2102-ECO

TABLE OF CONTENTS

1 GENERAL DESCRIPTION................................................................................................................................1

2 DESIGN .............................................................................................................................................................1

3 OPERATION......................................................................................................................................................1

3.1 Start-up........................................................................................................................................................2

3.2 Changing lubricant barrel ............................................................................................................................3

4 SETTINGS.........................................................................................................................................................3

5 TECHNICAL SPECIFICATION..........................................................................................................................4

5.1 Technical specifications ..............................................................................................................................4

5.2 Connections ................................................................................................................................................4

5.3 Symbols ......................................................................................................................................................4

6 LID SETS...........................................................................................................................................................5

7 SPARE PARTS..................................................................................................................................................5

7 APPENDICES


2102ECO2FEN.doc 19.05.2003 Rev. 2F

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PUMPING CENTER SG-2102-ECO

1 GENERAL DESCRIPTION

The pumping center is designed for pumping lubricant into the system.

2 DESIGN

Note Numbers in brackets are part numbers in the drawing 461576A.

Pumping central comprises of a hydraulic part (pos. 1) and barrel pump (pos. 2) and their additional equipment. The center is equipped with a compressed air regulator/oiler assembly (pos. 3) and a grease filter (pos. 4). The hydraulic part includes solenoid valve group (pos. 5) and control valve group (pos. 6). Solenoid valves control the pump and control valve operation.

The pump is delivered with the following additional pieces of equipment: lid set (pos. 7), follower plate (pos. 8), barrel low level switch (pos. 9) and an air gun for lifting the follower plate (pos. 10).

Note Do not use follower plate with grease or oil of classes NLGI 0, 00 and 000.

3 OPERATION

During pressurization, control center opens both the line to be pressurized and the pump solenoid valves. Pneumatic system starts the pump and opens the line control valve. Pressurization is continued, until pressure control unit reading reaches the acknowledgement pressure level. After acknowledgement, control center closes the solenoid valves, the pump stops and the pressure in line is relieved into the lubricant barrel.

If the lubricant level in the barrel reaches the low limit level, low level switch sends an alarm to the control center and pumping is stopped. The alarm can be disabled by changing the lubricant barrel and acknowledging the alarm at the control center.


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3.1 Start-up

Note Numbers in brackets are part numbers in the drawing 461632C.

1. Ensure that the surroundings of the pumping center are clean. Any impurities in the system

prevent trouble-free operation and cause damage when reaching the lubrication point. 2. Check the state of the lubricant barrel (1). Damages on the surface prevent the lowering of

follower plate (2). 3. Remove the lid from the barrel and press the follower plate tightly to the barrel above the

lubricant. Ensure that air is being removed under the follower plate and the central unit of the follower plate (3) is filled with lubricant.

4. Place the lid (4) on top of the lubricant barrel. Fasten the lid with wing screws on the lubricant barrel.

5. Place the pump (5) through the lid into the central unit. Ensure that the pump is attached to the follower plate.

6. Connect the pressure air hoses (6) to the solenoid valve group and the tank hose for lubricant (7) and high pressure filter (8) to the directional valve group (Fig. 1).

7. Fasten the low level switch (9) to the pump. 8. Connect the low level switch cable (10) to the pumping center as described on electrical

drawings. 9. Connect the hose for pressure air to the pressure air connection (12) on the pump. 10. Ensure that the lubrication device (14) for compressed air regulator/oiler assembly (13) is

filled with recommended oil. 11. Adjust the pressure air lubrication in pumping center with lubrication control device (15) of

compressed air regulator/oiler assembly. Recommendation: 1 drop of oil / 5 seconds when pump is in operation.

12. Set the pressure of pumping center pressure air to 4 bar (17) with pressure air control device (16) of compressed air regulator/oiler assembly.

13. Fasten the plug to the tank connection (18) of the pump. 14. Connect the pressure hose (19) to the pressure connection (20) of the pump. 15. Start the pump in manual operation state of control center or with pressure air manual

control screw (21) of pumping center's solenoid valve group. 16. After the pressure hose is filled, stop the pump and connect the hose to the high-pressure

filter. 17. Fill the main header with lubricant by starting the pump in manual operation state of control

center or with pumping center's solenoid valve group's pressure air and manual control screws of lubrication lines (22). Stop the pump when the main header is filled and air is removed.

18. Connect the tank hose to the tank connection. 19. Ensure before connecting the tank hose that only grease (no air) is coming out of the hose.

If needed, pressurize the system again. Pressure air in the system prevents its trouble-free operation.

20. Do a test pressurization of main header by increasing the pressure with a pressure control device up to 250 bar (23) on the pumping center. The pump will stop due to backpressure on 250 bar if there is no air or leakage in the main header.

21. Set the maximum pressure of pumping center with a pressure control device. The maximum pressure of the pumping center should be set approximately 20 % higher than the pressure by which the pressure control unit reaches the acknowledgement pressure level. For example, if the acknowledgement pressure level is reached when the pressure of pumping center is 170 bar, the maximum pressure should be set at 200 bar.


2102ECO2FEN.doc 19.05.2003 Rev. 2F

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3.2 Changing lubricant barrel

Caution Make sure that no impurities can enter the pump, follower plate or the lubricant barrel during the reservoir change procedures.

Caution Clean or change the grease filter cartridge when you are changing the barrel.

1. Ensure that the surroundings of the pumping center are clean. Any impurities in the system

prevent trouble-free operation and cause damage when reaching the lubrication point. 2. Switch off the power on the pumping center when changing the barrel by switching the

main switch on the pumping center to OFF position. 3. Disconnect the hose for pressure air (6) and the pressure hose for lubricant (19) and tank

hose (7) from the pump (5). 4. Lift out the pump from the lubricant barrel and place it on the pump bracket or on a clean,

e.g. plastic base. Be careful not to damage the suction part on the bottom part of the pump.

5. Remove the lid (4) from the top of the barrel. 6. Remove the follower plate (2) from the bottom of the barrel with an air gun (24). Feeding

pressure air through the central unit (3) under the follower plate loosens the follower plate. 7. Lift out the follower plate from the barrel with the help of handles. 8. Change the new lubricant barrel to replace the old one. 9. Press the follower plate tightly to the barrel on top of the lubricant. Ensure that air is being

removed under the follower plate and the central unit of the follower plate is filled with lubricant.

10. Place the lid on top of the lubricant barrel. Fasten the lid with wing screws on the lubricant barrel.

11. Place the pump through the lid into the central unit. Ensure that the pump is attached to follower plate.

12. Connect the hose for pressure air and the pressure hose for lubricant and tank hose to the pump.

13. Clean the lubricant filter (8) and change if needed. 14. Switch the power on to the pumping center by switching the main switch on the pumping

center to ON position. Reset possible low level alarm by pressing the "Alarm acknowledgement"–button on the control center.

15. Make a pumping center operation test run by pressing "Extra lubrication" –button on the control center.

4 SETTINGS

Warning The pressure in the compressed air system must be regulated so that the pressure at the control center cannot under any circumstances exceed 350 bar.

In SafeGrease 2 system, the pressure ratio of the pneumatic pumps used is normally 1:50. The pressure level in the pneumatic system can be set at 4 to 7 bar with the pressure limit switch located at the control device unit of the pumping center, in which case the line pressure generated by the pumping center is 200 to 350 bar.


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5 TECHNICAL SPECIFICATION

5.1 Technical specifications

Value Range Unit Description

t -10…+50

°C operation temperature

p 4–7

bar pressure range for pneumatic system

U 24 ±10% 115 ±10%; 50/60 230 ±10%; 50

V DC V AC; Hz V AC; Hz

control voltage

5.2 Connections

Input • compressed air, pipe Ø 12 mm or Ø 1/2”

Output • lubricant, 2 pcs (line 1 out; line 2 out), pipe Ø 12 mm or Ø 1/2”

5.3 Symbols

SG-2102-U-xxxV Abbreviation Description

SG: SG lubrication system type, SafeGrease 2102: 2102 model, dual line hydraulic system U: no symbol connections, pipe connections (mm) U connections, pipe connections (inches) xxxV: no symbol control voltage, 24 V DC ±10% 115V control voltage, 115 V AC ±10% 50/60 Hz 230V control voltage, 230 V AC ±10% 50 Hz

Example:

SG-2102

lubrication system type, SafeGrease

model, dual line pumping center

control voltage: 24 V DC

connections: pipe connections (mm)


2102ECO2FEN.doc 19.05.2003 Rev. 2F

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6 LID SETS

See 1/8-35-ECO-A-ALE-300 lid set assembly (drawing 360940A)




7 SPARE PARTS

See Spare parts for SG-2102-ECO pumping center (drawing 361107)

pumping center sg-2102-eco - lubriflexsafegrease 2 sg-2102-eco 2102eco2fen.doc 19.05.2003 rev. 2f 2...

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