Internal Timer Control Manual - Grease Pump
Contents
1. MDMM is used for indicating the fault status of au tomatic lubrication system to user such as leakage and blocking through detecting the pulse signal from the piston detector mounted on metering device Its automatic lubri cation cycle is variable according to the configuration of system Users are allowed to monitor the status of lubrication system through LED equipped on the products and indicator connected with cable from the product Available external equipments are as below e Low level sensor X e Compulsion operation and Pause switch e Piston detector for monitoring operation of metering device X During the car is running the operating time and pause time is memorized periodically 3 2 Specification tem Specification Rated Voltage 12 24 VDC Surge Overvoltage amp Inver se Voltage protection Consumption Current Max 25mA Controller solo specification POWER Control Output Motor NPN NO 1 Point Protection from overcurrent by external fuse 10A of controller Lamp for indicating NPN NO 1 Point Protection from overcurrent pump operation PNP NO 1 Point with max 250mA at reset overcurrent returns automatically Compulsion operation NPN NO 1 Point Detecting sensor at keeping and Pause switch more than 1 5 sec Low level sensor NPN NO or NC 1 Point Detecting sensor at keeping more than 3 sec Control Input Piston detector for monitoring operation of metering device NPN pulse 1 Point Detecting se2. Internal Timer Control Manual Grease Pump e HP 103 I for HP 103 Pump e HP 103 I B for HP M127 Pump Caution Functions marked with an X are not available for the HP 103 I B pump Table of contents 1 Preface to the Uses Manual ssssunsnunnnnnunnnnnnnnnunnnnnnnnnnnnnnn 3 Ded SME Wal aaa E E NA AAS 3 1 2 Users Responsibility ssssssussssnssnssnnununnsnnenenennnsnnannnenensennnnns 3 2 Safety INStr UCtIONS sasccananincsdndeeemieuccenciecnneenestvenineneieaunensutan Al 2 1 General safety instructionS s s sesesesererersrnnnnnnnnnnsnnnnnnsnnasnnernas 4 2 2 Exclusion of liability sssssssensessnenererersnnnnnnnnrnnnnnnrnnnsrensnrrrnnne 4 2 3 SYyMDOI explana ONS vacasenaneressvawepsresatecweeanecuesrsieesaeveeeneane 4 3 Product description sssssss222u2222 252220222222220202222202 222 2 0 5 ay A E A E EE E TTET E 5 JA SPO CNCA OIN atiacesananecd si EErEE EEn EEE 6 A General Mode ssssssusus222222252 222202 2 22220252 22222 2 2 2 2 2 s 8 7 4 1 Operation timing table ssssssessnssrsrensrsrrnrnnerrrrnrrerrenrnrerernn 7 eE POU We E E E E T E E T T 7 4 3 Operating TIME s sssssssssrsssrrrnsnnrnrnsrensrnrnrnrnsnennrnrnrrrnrrnrnenen 7 oe WS O aa N AEE 8 5 Metering Device Monitoring Mode ssssssssssusnnnuunnnnnnnnnnnnne 9 5 1 Operating Timing Table siusccsccscsssimesssoisasaacsneseisenanesacteseeiennn 9 a Pee WS Er EE E N 9 3 3 Operating TIME srren A RDS 9 gak MONON Mili er e e ee er r
3. d or contaminated lubricants as well as of com ponents that have been in touch with lubricant caused by unauthorized modification of the system components caused by insufficient use of power voltage caused by the use of unapproved parts 2 3 Symbol explanations The following pictograms and signal words used in this manual give the seriousness of danger z elek B Warning refers to faults or serious damages Caution refers to serious damages Caution refers to possible damages from misuse of electric devices Note refers to improvements in handling of systems Caution refers to possible fire and explosion 3 Product description 3 1 Summary This controller is designed to operate automatic lubrication pump in accordance with the control sequence The control sequence is repeated regularly with its operating and pause time During set pause time pump stops And then during set operating or monitoring time pump operates At the operating time grease is being distributed to each lubrication point through element of pump connected to a metering device This cycle is repeated regularly Pump operation ways are determined according to below 2 types of mode In addition to monitor grease level of pump Low level monitoring mode is equipped with In the General Mode GM a pump operates during set time operating time same as pause time Therefore automatic lubrication cycle is regular in this mode Metering Device Monitoring Mode
4. depending on the position of the red colored rotary switch 12 3 f4 5 s 7 8 9 ja B c D_E IF _ 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 2 4 e a 10 12 14 16 18 20 22 24 26 28 30 5 Meetapparaat modus X WAIN BI y 2 In case of that the MDMM jumper of J2 attached left pictures is connected control device is changed from General Mode to Metering Device Monitoring Mode When the pump is in pause or operation the changed set value is applied from next operating time JN The definition of the pulse signal of Metering Device Monitoring Sensor means that status shall be changed twice To reduce an effect from noise controller shall recognize that it is a change of status to sustain signal more than 500ms 5 1 Werkrooster Ss Sensing the pulse signal from the piston detector Yj SPORET gt E A y E Z a e Biia y LN Witla UUM A To Tp Ss System Vehicle Run State Sp Pause State So Operating state Te Luberication Cycle Tp Elapsed Pause Time To Elapsed Operating Time Tsm Setted Monitoring Time 5 2 Pause Time Same as General Mode 5 3 Operating Time In operating mode pump is operating until pulse signal is input from sensor attached on one outlet to monitor Metering Device operation It means time When the pump is operating metering device operates a piston of an outlet orderly and distributes grease into each lubrication point If distributing
5. e Q o Q O SW3 If SW3 Tact Switch located on the center of controller is pushed more than 2 sec or SW4 Reed Switch located on the upper of controller is reached with magnet more than 2 sec the status of pump is changed from operating to pause or from pause to operating compulsorily At switching u to operation mode pump operates for set operation time SW4 8 Factory Settings P I Operation Mode 9 sksisivdsansuenetcaswvadedvaianadneavewcwvanseudaes General Mode Q gt LOW level Monitoring cceccecececeeeeceeeeeeeeeeaeeeeeeeeeneaneneneas NO Disabled Pause Time ana 6 Hours HP 103 I 4 Hours HP 103 I B Operation Time 6 Minutes HP 103 I 16 Seconds HP 103 I B 9 Fault Diagnosis and Trouble Shooting 9 1 Fault status If fault occurs pump stops to operate And User can recognize fault status from LED which is equipped on the products and lamp connected externally Following articles show how to know each fault according to blinking pattern Fault Unang Cyel Fault status and cause Classification sec A 0 25 Error of EEPROM for storing status information of pump operation 0 Lack of grease in pump Low Level X e During monitoring time pulse signal is not detected from metering devic operation monitoring sensor C 1 Lubrication point or metering device operation fault Blocking due to some material air e Detection sensor fault e Sensor cable fault 2 D f 2 Time set rotary s
6. e and its design shall neither be modified nor transformed e The pump shall be operated properly only if it is in a proper functioning condition and if it is operated in accordance with the maintenance requirements e The operating personnel must be familiar with this operation manual and the safety instructions mentioned herein and observe these carefully e Wastes e g used oil detergents lubricant must be disposed in accordance with relevant environmental regulations 2 Safety Instructions 2 1 General safety instructions The safety instructions shall be observed when the pump is installed operated and serviced Custom the personnel responsible for the handling of the system should wear pro tective gears and glasses for safety Working environment the pump must be free from inflammable materials Working environment should be clean all the time Maintenance before repair or maintenance power should be switched off Cleaning during the operation of the pump cleaning should not be carried out During cleaning the personnel should wear mask protective gears and shoes To be protected from toxic gas working environment should be well ventilated 2 2 Exclusion of liability caused by lack of lubricant due to irregular refilling of the pump caused by the use of contaminated lubricants or insufficient lubricants caused by chemical or biological modifications of the lubricants used caused by inadequate disposal of use
7. e ere er ee tes eee ee riin 10 Se WS Se ONG 2g actetansesanccecnecneeaeonatecsaceran esceneeanssetsencrseecesseenenes 10 6 LOW NEVE siincindeiadeierinncsccenisvencenvandinartaiendrcedes AEA 11 6 1 NO input Factory setting s sesssssssssssssnssnnsensnnnununnsnnnnnnensnnnne 11 6 2 NC Input Customized ssssssssssssesnnnssunnsnsennnensnsnnnnnnnnsrnnnas 11 7 Compulsion Operation Mode and Pause MOde cccsseesseesees 11 8 Fact ry Setting iscissi anaa 12 9 Fault Diagnosis and Trouble Shooting ssssss22222 n 12 ele FU ot e E E E EEE E T E E 12 9 2 Fault Clearance asssssssesssensnnunnnnnnnnnnnnnsnsnsnunnnnsnsnnnnennnsnnnnnnns 12 10 Wiring Dia grani a2 checiiscaveeenteduruieccenneseussiseseisieandvausinesncndenenn 13 1 Preface to the User Manual 1 1 General The operation instructions contain important information for safe and right operation of internal grease pump controller HP 103 I or HP 103 I B It is recommended that a user must read the instructions carefully prior to operation as we can t take on any lia bility for damages and failures resulted from non observance of the instructions These instructions must be completed to include the respective national regulations concerning to accident prevention and environment protection 1 2 Users Responsibility To ensure the safe operation of the pump the user is responsible for the following e The pump shall be operated only for the intended us
8. e red colored rotary switch 1 2 3 4 5 e 7 s 9 fa B c p JE F 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 2 4 e a 10 12 14 16 18 20 22 24 26 28 30 6 Laag niveau sensor Ay 1 2 Available Low level sensor type is NPN and NO Normal Open If customized NC Normal Close is available To make strong against noise if low level signal is not kept more than 3 sec it is not recognized 6 1 NO input Factory Settings B E a PN In case of that LLS jumper of J2 is removed controller detects NO signal from LowLevel sensor equipped in pump to indicate fault status B and lack of grease In case of that the LLS jumper is connected Low level signal is sent to controller instead of the sensor Then It can be used for checking if the sensor is fault or not Low level sensor uitgang op de ingang naar de controle unit contacten zal NO normaal open van het NPN type moeten zijn 6 2 NG input Customized c s STI LX In case of that LLS jumper of J2 is removed controller immediately detects NC signal from Low level sensor equipped in pump to indicate fault status B and lack of grease In case of that the LLS jumper is connected controller immediately stops to monitor grease level Low level sensor output on the input to the control unit contacts should be NC Normal Close of NPN type 7 Compulsion Operation Mode and Pause mod
9. grease into all outlet is completed one time the equipped sensor on the one outlet instead of a piston generates pulse signal While the metering device is operating even though the system stops or power is disconnected elapsed operating time is stored It is different depending on system configuration 5 4 Monitoring Time e Monitoring time for metering device operation Fault C e Set value can be changed by using red colored rotary switch e When the lubrication system is stopped or disconnected with power elapsed time is memorized in EEPROM And if the system continues or power is connected it operates based on memorized time e If set value is changed on the pump pause or operating time the changed set value is applied in next pause time e It is different depending on system configuration 5 5 Time Settings e Unit Time Setting The unit time of monitoring time and pause time is set depending on the position of below jumpers Jumper position ee Unit time of Pause Hour Minute Minute time Unit time of Minute Second Minute Second Monitoring time e Pause Time It is available to change 15 set values depending on the position of the blue colored rotary switch 1 2 3 4 5 ls 7 8 9 JA B c D JE F 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 2 3 4 5 j6 7 8 j9 10 11 12 13 14 15 16 e Monitoring Time It is available to change 15 set values depending on the position of th
10. nsor when each status is being sustained more than 500ms Timer Pause time 4 60 min 4min interval 15 range 1 15 hours ihour interval 15 range Operation Monitoring 8 120 sec 8sec interval 15 amplitude time 2 30 min 2min interval 15 amplitude Available pump model Hyunbo HP 103 HP 103 1 HP M127 HP 103 I B Other company P203 HP 103 I MLP HP 103 I B conne Time 6 sec HMC Standard ES96202 01 Electrostatic Discharge ES96200 00 Ver G X Blue rotoary switch for setting the Red rotary switch for setting the operating or pause time monitoring time 5 Power o sy Status LED g HP WEEE B LED Jumper for j setting Switch the time for a anit forced operating pause or fault clearance iF 20 OD 4 Sag Jumper for inactivating the low level mointoring mode only NO input type x Jumper for activating MDMM X 4 General Mode In case of that the MDMM jumper of J2 control device is changed from Metering Device Monitoring Mode to General Mode When the pump is in pause or operation the changed set value is applied from next operating time WAGW IS 4 1 Operation timing table ZI WE pran g 50 Tp To Tp To Ss PEETER State Sp Pause State So Operating state Te Luberication Cycle Tp Elapsed Pause Time To Elapsed Operating Time 4 2 Pause Time Pause time means the time that pump doesn t work and it determines the period of automatic lubrication Gene
11. rally pause time is extremely longer than operation time Set value can be changed by blue colored rotary switch When the lubrication system is stopped or disconnected with power elapsed time is memorized in EEPROM And if the system continues or power is connected it operates based on memorized time If set value is changed on the pump pause or operating time the changed set value is applied in next pause time It is different depending on system configuration 4 3 Operating Time It depends on the quantity of distributed grease in the lubrication system Set value can be changed by using red colored rotary switch When the lubrication system is stopped or disconnected with power elapsed time is memorized in EEPROM And if the system continues or power is connected it operates based on memorized time If set value is changed on the pump pause or operating time the changed set value is applied in next pause time It is different depending on system configuration 4 4 Time set e Time unit set Time unit of operating time and pause time is set depending on the position of below jumper Jumper Position e Pause Time It is available to change 15 set values depending on the position of the blue colored rotary switch 1 2 3 4 5 s 7 a 9 a B c p JE F 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 1 2 3 4 5 js 7 8 9 10 11 12 13 14 15 e Operating Time It is available to change 15 set values
12. witch set error O position 9 2 Fault Clearance Method Fault Fault status and cause Classification Automatic B In case of the cause of fault is removed Clearing D In case of that power is reconnected after power is A B C D disconnected AN Possible to clear compulsory in case of A but if fault Compulsory occurs frequently the product is needed to replace Clearing e If button is equipped inside of product and compulsory operation switch connected externally B C ee are pushed for around 2 seconds it is cleared compulsory 10 Wiring Diagram tis net available oe age in HP 103 B version 31 30 15 M a HZ amp Z fp E pes Sw tch for foc2ed Ozera tng AA fe fy Use COA D i tausej ar Fau 7 Cleavance E Do Motor E Status Lanp T w Level Senscr Fi F sion Deco Senzor Terminals of the printed circuit board Signal lamp Additional lubrication Level control gt Low level control Low level control Motor Motor Machine contact or driving switch VDC Contact 30 Example bridged with contact 15 Earth 0 VDC T PCBv 040a10 Terminals of the printed circuit board V10 V13 contact 15 30 bridged
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