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Manuale d`uso e manutenzione

1. lt 4 NERO Pulsante luminous indicator 5 VIOLA Lampada spia lumi 5 For information on how to connect the harness to the electropump see the diagram referred to the selected version and the one below lamp with voltage above 24 should be used for 110 220 versions 23 Connect the electropump to the electric system of the vehicle or of the machine on which the lubrication system is installed Part 1 General considerations Page 43 CIAPONI Industry LUBRIFICAZIONE CENTRALIZZATA 1 6 2 WIRING DIAGRAM VERSION 12 24 V DC VERSION WITHOUT TIMER OR WITH TIMER PAUSE WORK Schema elettrico pompa 12 24V DC Timer Pausa Lavoro 12 24V DC M oshi Connettore A Stabiliz ositivo E Blu Mosfet N 12 24V b zatore m Motore Fuse 10A max Diodo _ M 12 24 DC Negativo low o Marrone Marr
2. 18 SECONDARY PIPE usui assu tad a 19 DISPENSE 19 DOUBLING 0FFEOW RATE uoi vnda d ca ey 25 e BRIDGE OUTPUT 00 2 2 2 000110000 1 26 INDICATOR PULSE OF VISUAL INSPECTION eene 26 uec RH ICM CE 26 Aa o cam MC NNU ICE E 27 MERC SIS HERD CHE elia 28 o EXTENSION c mem 29 HME R Gellar 30 JPAUSE WORKING CYCLE csisisontt ciao 31 PAUSE SENSOR WORKING CYCLE sula 31 1 4 7 SENSOR CONTROL WORKING 5 5 31 SENSOR CODE 095032 FOR AUTOMOTIVE 31 e SENSOR CODE 095010 FOR INDUSTRY 32 14 8 MINIMUM LEVEL Lm 33 CIAPONI LUBRIFICAZIONE CENTRALIZZATA 1 5 0 STORAGE 34 1 6 0 ASSEMBLY MEM ELE 34 1 6 1 OPERATING PROCEDURE 35 e FPIECIROPOMP tte ET et 36 e PUMPINGELEMENT 37 e FITTINGS 37 e DIOFENSE ee a E ee eee 38 e OGEN OR ce E EE EE E E 38 MAIN AND
3. 1 4 NERO Pulsante 5 VIOLA Lampada spia luminosa max 15 W Ce CG TT im amp w 1 GIALLO VERDE Terra w mm 2 BLU Neutro 3 MARRONE Fase 1 2 BLU The cable derived from the A to the body pump it must be connected to the electrical supply system and with the light button of the remote control device code 110001 The harness comes with about 600 mm of the sheath The Cable 2P power sensor code 150050 derived from the S of the pump body must connected to the B sensor as for version 12 24 V DC The minimum level signal is controlled by the electronic control e REMOTE CONTROL DEVICE 22 versions with control timer pause sensor install the luminous indicator of the Remote control device Cod 110001 on the control board of the machine or vehicle It is possible to use both Dispositivo di controllo a distanza Cablaggio dispositivo schema collegamento elettrico th e 1 2 2 4 V d di controllo a distanza pulsante luminoso Mod 16 1 24 110 220 V remote 3 MARRONE Massa control device 2 ROSSO VERDE Tensione The figure shows the versione Automotive pa 2 wiring diagram for the
4. LUBRIFICA ZIONE CENTRALIZZATA EUR 3 CENTRALIZED LUBRICATION SYSTEM OPERATION AND MAINTENANGE MANUAL PART 1 GENERAL CONSIDERATI 5 2 2 0 7 4 OVERVI EW OF THE COMPANY 4 MANUFACTURER S 4 CUSTOMER SERVICE scarica aaa 4 GENERAL WARNINGS nonien tr e A 5 SYMBOL LEGEND i ica 5 SCOPE OF THIS MANUAL 25 2 RR 5 HANDBOOK STRUCTURE i rois adv Dico etie me EUN 6 SAFETY STANDARDS APPLIED ai 6 DECLARATION OF CONFORMITY ul 7 1 1 0 RECOMMENDED USE 3 3 ccn Det are ce iaia 8 120 OS d bde M 9 1 3 0 5 5 9 1 4 0 TECHNICAL 5 52222500555 10 Tu D ELECTROPUMP 10 14 2 P UMPINGJEBEMENDNrT accelera 14 SIGNALING VALVE with recirculation of grease nennen 16 e SIGNALING VALVE with ejection grease iii 16 e electa 17 1 4 18 MAINPIPE
5. Figura 10 In orinary operating conditions the external signaling valve is located in the inactive position OFF Spin down At the moment in which the pressure output from the pump reaches the value of 250 bar the valve moves progressively in signaling position ON Spin high After you restore the correct functioning of the system Is necessary to verify that the indicator has returned to normal operating position In the event of overpressure circuit the grease falls into the pump from the pumping itself e Do not modify or remove the safety valve outside CIAPONI LUBRIFICAZIONE CENTRALI ZZATA s r l disclaims any liability for damage caused by tampering with the safety valve outside e In case of malfunction of the safety valve outside IMmediately contact Customer Service e SIGNALING VALVE with ejection grease Figure 11 shows a version of the pumping element wich can be supplied as optional with an external signaling system that controls the inlet instead of the safety valve with ejection grease Part 1 General considerations Page 16 CIAPONI LUBRIFICAZIONE CENTRALIZZATA The components shown are Pumping Washer 3 way shunt Signaling valve 90 fitting Manual lubricator x9 D SCHEMA DI FUNZIONAMENTO Cap Figura 11 At the moment in which the pressure output from the pump reaches the value of 250 bar the valve moves progressively Signaling position ON Spin hi
6. outlet 1 and or 3 RET e Loosen and remove the with IL gt I A from the outlet where the pumping unit has to be installed e Insert and tighten the pumping element in the selected configuration e Tighten the pumping element with a torque of 20 Nm ATTENTION the position of the driving cam may hinder the tightening of the pumping element In this case it is necessary to install the pumping unit on one of the other outlets or introduce the pumping unit making sure that the threads are correctly arranged e FITTINGS Remove the lubricators from the bearing points of the automatic system that require lubrication 5 Tighten the fittings of the bearing points NB use extensions for the fittings if difficulties arise due to the lack of space or incorrect positioning of fittings on the bearing points Otherwise remove the screw caps 7 Tighten the inlet fitting of the dispenser where the main pipe has to be connected Tighten the fittings of the dispenser that has to be used NB the dispenser is generally supplied without the outlet caps required for the dispensers Part 1 General considerations Page 37 CIAPONI LUBRIFICAZIONE CENTRALIZZATA DISPENSER Install the dispenser leaving a distance of at least 50 mm from equipment and obstacles that could prevent the acce
7. 3 Button TEST 4 Button ENTER Figura 23 Part 2 Operating manual Page 48 CIAPONI LUBRIFICAZIONE CENTRALIZZATA Loosen fixing screws and remove This operation gives access to the timer for digital the cover to access the timer programming Press ENTER for 3 seconds The display turns on and shows letter P Pause Briefly press ENTER The display shows the value set for parameter P Every time the button is pressed the displays Press TEST to change the value of shows in sequence the digits and letters of the parameter P pause time settings shown in the table displayed value is stored as current value for Briefly press ENTER to confirm the 05 parameter the display shows once more setting letter NB For versions with Pause Sensor control timer skip directly to operation 10 because ra the only parameter that can be set is the pause time P The display shows letter L working time Press TEST to alternate the display of NB it is useful to remember that TEST Jj parameters P and L enables to alternate the display of letters P or L Briefly press ENTER The display shows the value set for parameter L Every time the button is pressed the displays Press TEST to change parameter L shows in sequence the digits and letters of th
8. Code Descrizione 021 CH CH1 L Straight recyclable fitting 696 10 14 59 10 14 59 Code Description 0 01 1 L1 L2 7 3 16 pipe Code Description 0 1 CH CH1 L1 Straight recyclable fitting 6 9 6 12 14 36 00750 1 8 pine 12 14 36 Code 0 01 L1 12 s ge oe a a 1 8 pipe Boccola Tubazione recuperabile primaria Figure 18 show the operations that have to be in senso performed to assemble the main pipe with antiorario recyclable fittings To facilitate and allow a correct assembly of the Inserto recuperabile fitting it is necessary to grease the internal and external surfaces of the area where the fitting is inserted Avvitare senso orario Figura 19 Part 1 General considerations Page 27 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e QUICK FITTING Quick fittings are in nickel plated brass The fitting with conical metrical or gas threading guar
9. 095502 Dispensing element 0 05 cm oo 3 095503 Dispensing element 0 10 cm 095504 Dispensing element 0 25 EL See the previous table commercio 095020 Gasket set initial element 095019 Gasket set dispensing element 2 1 sse 19 ingresso lubrificante attacco tubazione principale 4 secondarie attacco sensore attacco tubazioni 7 2110 2550 Figura 1 Part 1 General considerations Page 21 Industry CIAPONI LUBRIFICAZIONE CENTRALIZZATA TABLE E which refers to Figure 15 specifies the overall dimensions and the weight of the progressive dispenser without fittings depending on the number N of dosing elements The technical specifications of the progressive dispenser are Number of dispensers that be assembled ___ Operating temperature Operating pressure min max Max number of cycles per minute Dispenser flow rate per cycle Inlet fitting Outlet fitting Cycle electric control optional from 3 to 10 from 30 C to 100 C 10 bar 400 bar 300 0 05 cm 0 10 cm 0 25 M10x1 threading M10x1 threading By means of the sensor connected to the pause operating The following diagram describes the o
10. to which it is connected through the main pipe The dashed path identifies the flow of lubricant prepared disbursement The course identifies the white pipes in which the lubricant is not under pressure The progressive numbering from 1 to 6 identifies the outputs of which are connected to the secondary pipes that carry the lubricant flow in the flow required to lubricate the various points bearing Page 22 CIAPONI LUBRIFICAZIONE CENTRALIZZATA The stretch in white identifies the ducts in which the lubricant is not under pressure The progressive numbering from 1 to 6 identifies the outputs of which are connected to the secondary pipes that carry the lubricant flow in the flow required to lubricate the various points bearing STEP 1 The flow of lubricant under pressure moves the piston A to the right enabling the delivery from the 1 This movement prepares the lubricant under pressure to the shift of the piston B STEP 2 The resulting shift of the piston B to the right allows the delivery exit 4 and prepares the lubricant under pressure to the shift of the piston STEP 3 Moving to the right of the piston allows allows the provision junction 6 and prepares the lubricant under pressure to the shift of the piston A STEP 4 Moving to the left of the piston A allows the delivery from the 2 and prepares the lubricant under pressure to the displacement of the piston B STEP 5 The shift of the pi
11. 0 TIMER 48 2 3 0 TANK FIELING 51 LUBRIFICANTI 51 2 NI STARUP 52 2 4 1 OPERATING PROGEDUIPBE ie basta to tuam ite dTa elastane 52 PART MAINTENANCE INSTRUCTI 44 4 10001 53 3 1 0 MAINTENANCE INSTRUCTION 222224 112 011111 53 Part 1 General considerations Page 2 CIAPONI LUBRIFICAZIONE CENTRALIZZATA 3 2 0 SCHEDULED MAINTENANCE Ju 53 5 3 0 54 1 General considerations Page 3 CIAPONI LUBRIFICAZIONE CENTRALIZZATA PART 1 GENERAL CONSIDERATIONS OVERVIEW OF THE COMPANY CI APONI LUBRIFICAZIONE CENTRALIZZATA s r l is specialized in the design manufacture and installation of centralized lubrication points The company which initially produced industrial vehicles only has developed in the years thanks to the vast experience acquired earth moving machines and machinery for industrial applications Its dynamism has led it to upgrade its engineering manufacturing and quality control systems with state of the art solutions The Quality Control System adopted by the company was certified in 2001 as compliant with the requirements of standard
12. LUBRICANTS The table that follows lists the codes for the main and secondary pipes used for the centralized lubrication system IMPORTANT To order a main pipe with pressure bushings use the code 00630 00760 associated to the description pressure bushings and indicate a length in millimeters MAIN PIPE The main pipe is used to connect the pumping element to the progressive dispenser This pipe consists in an hydraulic anti lt lt H S INN abrasive pipe with very high chemical and physical characteristics with a sub layer in thermoplastic polyester a reinforcement consisting in 2 polyester braids and in black polyurethane thermoplastic and coating The polyurethane used for external coating offers a high resistance to abrasion and environmental agents i e salt water micro bacteria ozone etc The technical specifications of the main pipe are Compliant to standards SAE 517 sez SAE 100 R7 EN855 1503949 Main pipe code 00630 00760 External diameter 3 16 inch 9 6 mm 1 8 inch 8 2 mm Operating temperature from 40 C to 93 C from 40 C to 93 C Minimum brust pressure at 20 840 bar 840 Minumum bending radius 25 mm 25 mm Weight 60 gr m 45 gr m Part 1 General considerations Page 18 CIAPONI LUBRIFICAZIONE CENTRALIZZATA SECONDARY PIPE The 6x1 5 secondary pipe 15 a type A single
13. SECONDARY PI PES 38 e ELECTRICAL CONNECTION 12 24 V DC 39 e VERSION WITHOUT TIMER OR WITH TIMER 39 e VERSION WITH TIMER 5 5 5 39 e VERSION WITHOUT TIMER OR WITH TIMER PAUSE WORK AND MINIMUM LEVEL 40 e VERSION with TIMER PAUSE SENSOR and MI NI 40 electrical connection 110 220 V AC 41 e VERSION WITHOUT TIMER OR WITH TIMER 41 e VERSION WITH TIMER 05 5 5 2 00000 0000000000 000000000 42 e VERSION without TIMER Or with TIMER PAUSe work and MINI LeVEL 42 e VERSION with TIMER PAUSe SENSOR and MINI LeVEL 43 5 COO aioe crease 43 1 6 2 WIRING DIAGRAM VERSION 12 24 0088 44 VERSION WITHOUT TIMER OR WITH TIMER 5 44 s VERSION WITH TIMER PAUSE SENSOR iater ideni 44 1 6 3 WIRING DIAGRAM VERSION 110 220 V DC 45 VERSION WITHOUT TIMER OR WITH TIMER 5 45 VERSION WITH TIMER PAUSE SENS OB utebare UE di rio 46 PART 2 OPERATING MANUAL 14 eese erre rennen nnn nana aan ERR RR REN auus 47 2 1 0 47 2 2
14. is the working component of the pump It is shrunk fitted directly on the pump housing and driven by means of an eccentric cam The suction system consists of a dual free channel while the discharge has an adjustable delivery valve The piston contains a safety and discharge valve that Immediately discharges the fluid inside the pumping element to avoid the building of excessive pressure that could potentially damage the system in the event of failure The components of the pumping element are in premium quality Figure 6 alloyed steel treated to offer a high resistance to wear A special superficial coating guarantee excellent resistance to corrosion which is tested by means of salt spray tests In the figure is shown the working scheme Figure 7 Completed the pumping phase of the delivery valve closes facilitated by the spring The return of the piston at BDC bottom dead center creates a vacuum inside the suction chamber cylinder through which the lights A is filled with grease Figure 8 left highlighted in light blue The piston begins pumping phase overcoming the backpressure created by the discharge valve and pumping the fat B in the plant Part 1 General considerations Page 14 CIAPONI LUBRIFICAZIONE CENTRALIZZATA The technical specifications of the pumping element are Bore 6mm Useful stroke 6 mm Capacity 0 17 Flow rate 2 8 cm min Weight 250 gr Safety valve Pmax 2
15. pump The detection system of the minimum level is supplied as optional and are not provided for adjuistment The electro mechanical characteristics of the magnetic sensor IS are Mechanical life 100 number of millions of cycles Switching frequency 250 pulses second Precision repeatability 0 1 mm Operating temperature From 20 to 60 Voltage 100 V DC 150 AC Max Power 10 W Max current 0 5 A Do not use inductive loads greater than 0 1 1 5 0 STORAGE The centralized lubrication system is usually supplied disassembled to customers Before forwarding the system CIAPONI LUBRIFICAZIONE CENTRALI ZZATA s r l adopts all the necessary measures to guarantee a correct packaging of all the components The user shall be responsible for storing all the components received by CIAPONI LUBRIFICAZIONE CENTRALI ZZATA s r l indoors in clean and dry rooms and at a safety distance from chemical and or corrosive substances CI APONI LUBRIFICAZIONE CENTRALI ZZATA s r l shall not be responsible for damages originating from the incorrect storage of the components described It is useful to remember that the user is fully responsible for a safe loading unloading and handling of the system 1 6 0 ASSEMBLY The operating procedure that follows describes the operations that have to be carried out to assembly the centralized lubrication system For information on overall dimensions weights and technical
16. s r l The Manufacturer may change the content of this manual at any time without warning for technical or commercial reasons or to comply with new standards or laws SYMBOL LEGEND Key to symbols for the correct text interpretation The symbols listed will be reported to the left of the text or in the vicinity of contents to which the reader should pay attention Q Prohibition signal it prohibits an action that could cause a hazard Prescription signal it prescribes specific behavior Electrical warning signal it warns of a risk or danger of contact with electrical parts Warning signal it warns of a risk or generic danger Education signal it feels you follow the instructions on the side SCOPE OF THIS MANUAL This manual supplies the user with all the information required to install use service and dismantle the system CI APONI LUBRIFICAZIONE CENTRALI ZZATA s r l shall not be responsible for damages faults caused by the failure to comply with the warnings and instructions provided below It is therefore advisable to Carefully read all the parts of the Operation and Maintenance Manual Keep a copy of the manual in a safe place and always make it available to all operators working with it Part 1 General considerations Page 5 CIAPONI LUBRIFICAZIONE CENTRALIZZATA HANDBOOK STRUCTURE The Complete Handbook is composed of the following parts Part 1 General aspec
17. specifications of the single components see Chapter 1 4 0 TECHNICAL DATA It is also useful to remember that Part 1 General considerations Page 34 CIAPONI LUBRIFICAZIONE CENTRALIZZATA These operations must always be performed by trained and qualified technicians The protection and safety devices fitted on the vehicle or machine should not be modified or disabled These devices may be removed during the installation of the system but must be reinstalled after the installation has been completed All centralized lubrication systems must be installed away from heat sources Centralized lubrication systems should not be installed in particularly aggressive environments with chemicals that could potentially damage the components of the system Welding and or drilling operations required to install the centralized lubrication system must be performed in compliance with the technical specifications of the vehicle or machine manufacturer Lubrication systems must be fitted only with the accessories supplied or certified by the Manufacturer 1 6 1 OPERATING PROCEDURE 0 Remove all the components of the system from the package 1 Visually inspect all the components of the system in order to detect potential damages originating from transportation or from an improper storage damages should be promptly reported to the Customer Service of CIAPONI LUBRI FI CAZI ONE CENTRALI ZZATA s r l Part 1 Gene
18. the electrical supply system and with the light button of the remote control device code 110001 Part 1 General considerations Page 39 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e VERSION WITHOUT TIMER OR WITH TIMER PAUSE WORK AND MINIMUM LEVEL 1 MARRONE 1 2 BLU 2 BLU The CABLE 2P power sensor code 150050 used for the connection is derived from the exit of the pump body marked with A From the position S is instead derived CABLE 2P minimum level cod 150051 e VERSION WITH TIMER PAUSE SENSOR AND MINIMUM LEVEL AN 1 Posizione vuota 1 lt 2 ROSSO VERDE Tensione sotto chiave 1 lt 3 MARRONE Massa n lt 4 NERO Pulsante 5 VIOLA Lampada spia luminosa max 15 W 1 MARRONE 2 BLU The CABLE 2P power sensor code 150050 derived from the S of the pump body must be connected to the connector B of the sensor While the connector code 150053 derived from the A of the pump casing must be connected to the electrical supply system and with the light button of the remote control device code 110001 The minimum level signal is controlled by
19. the electronic Part 1 General considerations Page 40 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e ELECTRICAL CONNECTION 110 220 V AC ATTENTION for the powered versions 220 110V AC 50Hz e All electrical components of the system shall be grounded This applies both to the electrical parts that for the control devices To do this make sure that the ground wire is properly connected For safety reasons in case of accidental disconnection of wiring the ground wire should be the last to be removed therefore the ground wire should be about 100mm longer than the phase conductors e Connection to the mains supply must be carried out between the electrical wiring of the lubrication system and the power supply a suitably selective differential magneto dimensionat In the following procedures always refer to paragraph 1 6 2 WIRING DIAGRAM e VERSION WITHOUT TIMER OR WITH TIMER PAUSE WORK w 1 GIALLO VERDE Terra 2 BLU Neutro 3 MARRONE Fase In the figure on the right is a diagram of a wiring connection is code 150052 The cabling is derived from the A of the pump casing and comes with about 600 mm of the Sheath Part 1 General considerations Page 41 Industry CIAPONI LUBRIFICAZIONE CENTRALIZZATA e VERSION WITH TIMER PAUSE SENSOR A ROSSO 28 30 V DC i lt 2 Posizione vuota 3 ROSSO VERDE M
20. the main and secondary pipes using common clips or straps ATTENTION do not fix or thread the pipes on vehicle or machine components that could overheat i e exhaust pipes motor etc Connect the pipes to the fittings Part 1 General considerations Page 38 CIAPONI LUBRIFICAZIONE CENTRALIZZATA Operation NB the main pipe is used to connect the pump to the dispenser the secondary one is instead used to connect the dispensers to the bearing points that require lubrications e ELECTRICAL CONNECTION 12 24 V DC 13 The figure shows the e WIRING 2P power sensor x S A code 150050 used for the D 7 lt En connection It is derived from the body of the pump marked A VERSION WITH TIMER PAUSE SENSOR 14 A 1 Posizione vuota 0 pelt oy ROSSO VERDE Tensione sotto chiave 1 lt 3 MARRONE Massa A XL ZA 1 4 NERO Pulsante S j SN VIOLA Lampada spia luminosa 15 W 1 MARRONE 2 BLU The CABLE 2P power sensor code 150050 derived from the S of the pump body must be connected to the connector B of the sensor While derived from the connector to the pump housing must be connected to
21. with the Sleep Timer Sensor Figura 21 The cycle begins with the contact of the sensor locked you spent the time programmed pause the pump enters the stage of work lubrication The actuation of the dispenser installed on it opens the contact sensor that reads Part 1 General considerations Page 31 CIAPONI LUBRIFICAZIONE CENTRALIZZATA the position of the beginning of lubrication cycle The subsequent actuation of the dispenser will close the contact and then the end of the work cycle with a consequent stop of the pump The technical specifications of the standard sensor are Degree of protection 68 Contact ON OFF Operating temperature From 30 C to 80 C 2 0256 0 10 CiaPoni Ciaponi 0 05 e SENSOR CODE 095010 FOR INDUSTRY APPLICATIONS This sensor has been designed to control the correct functioning of progressive systems for the Industrial Sector The sensor checks the movement forward return of the piston of the dispenser element During correct operation with a regular supply by the distributor the LED turns on and off alternately In case of malfunction the sensor is blocked in a state where it is located LED turned on or off according to the position
22. 5 3 3 0 ANOMALI ES This chapter provides information on e Possible problems that may occur during the operation of the system e The cause that may prevent the system from starting and stopping e Corrective actions NB the lubrication system with Pause Sensor control timer has luminous indicator that can be managed remotely If the indicator stays on permanently at the end of an operating cycle The grease in the tank may have fallen to the minimum level An anomaly has occurred within the system In both cases the Timer stops the system even after 10 minutes N cause 01 01 Check the power supply and the status No current of the fuse The pump motor 01 02 The electronic card is not Replace the electronic card doesn t work working 01 03 The reduction gear doesn t Replace the reduction gear 02 01 The tank is empty Fill the tank with clean lubricant 02 02 Air bubbles in lubricant Disconnect the primary tube of the The pump doesn t fitting of the pumping element Start the delivery lubricant pump manually until the lubricant expelled from the fitting is not perfectly cleaned Part 3 Maintenance Instruction Page 54 Industry The pump runs but Disconnect p no lubricant reaches the 03 01 03 02 04 01 bearing lubrication The progres points blocked The lubricant is distributed to the connected bearing lubrication points irregularly The suppl The dis
23. 50 50 bar Fitting Standard with G1 4 threading Figure 8 shows a pumping element with fitting for the connection of the main pipe which is supplied as standard The main components are Pumping element Washer 90 fitting Manual lubricator ae De Figura 9 Every pumping element is adjusted and tested by the manufacturer It is therefore advisable to Avoid changing the set points of the safety and delivery valve of the pumping element CIAPONI LUBRIFICAZIONE CENTRALI ZZATA s r l shall not responsible for damages originating from the tampering with the safety valve In the event of problems immediately contact the Customer Service Warning the flow value mentioned relates to the following conditions lubricating grease consistency class NGLI2 or oil 50 1000 cSt 40 C standard ambient conditions T 20 C p latm back pressure of 100 bar and motor from 20 rpm and rated voltage 12 24 V DC Part 1 General considerations Page 15 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e SIGNALING VALVE with recirculation of grease Figure 9 shows a version of the pumping element which can be supplied as optional with an external signaling system that controls the inlet instead of the safety valve with recirculation of grease The components shown are Pumping Washer 3 way shunt Signaling valve 90 fitting Manual lubricator ees YS SCHEMA DI FUNZIONAMENTO Cap
24. LIZZATA It is useful to remember that the Declaration of Conformity is valid only if The indications safety warnings and instructions given in the operation and maintenance manual are observed The system 15 used in accordance with the instructions provided by the manufacturer Adjustment operations are carried out by authorized trained and qualified personnel Maintenance operations are carried out by qualified and authorized technicians Failure to comply with the requirements listed in the Certificate of Conformity shall automatically invalidate the warranty 1 1 0 RECOMMENDED USE Centralized lubrication systems are designed to automatically lubricate points subject to wear after their identification Therefore they must be used only for the lubrication of the points to which they are connected Users are not allowed to apply unauthorized changes to an installed system Modifications must be carried out or authorized by the manufacturer only The system should always be used within the operating parameters specified in paragraph 1 4 0 TECHNICAL SPECIFICATIONS The system must be used only with the fluids listed paragraph 2 3 1 LUBRICANTS The Technical Department of CIAPONI LUBRIFICAZIONE CENTRALIZZATA s r l can be contacted for further information or feasibility studies The manufacturer shall not be responsible for damages originating from an improper use or the unauthorized modification of the system
25. RALIZZATA e BRIDGE OUTPUT CONNECTION This connection system is used when we want to increase the flow of grease or oil at a point of lubrication In carrying out this type of operation you must always keep in mind the grain to the central liaison for doubling the flow rate which in some combinations should be removed while others must remain inside the dispenser Hn case of malfunctioning of the bridge link or problem about the installation contact Customer Service immediately e INDICATOR PULSE OF VISUAL INSPECTION The movement of the pin actuated by the piston element on which 15 mounted the detector as shown in the figure allows visual control of the operation of the distributor and then the successful execution of the lubrication cycle The indicator is constructed in such a way that it can be installed on any metering element of the distributor 1 4 5 FITTINGS The fittings used for the centralized lubrication system includes both quick fittings and extensions for secondary pipes with a diameter 9 6 mm and recyclable fittings for the main pipe R7 The paragraphs that follow describe the technical characteristics and dimensions expressed in millimeters for each type of fitting Part 1 General considerations Page 26 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e RECYCLABLE FITTING These fittings which are made in steel or nichel plated brass are used to assemble the main pipe
26. The technical specifications of the standard sensor are Degree of protection IP67 Operating temperature From 25 C to 70 C Nominal distance of read 5 mm Operating voltage 10 30V DC Hysteresis lt 1090 working frequency 200 Repeatability lt 0 01 mm Max output current into DC voltage 100 mA load current 200 MA Short circuit protection Yes Led indicator Yes Voltage drop 18V Part 1 General considerations Page 32 CIAPONI LUBRIFICAZIONE CENTRALIZZATA Loss of amperage 1 8 mV Maximum pressure 350 bar N B During maintenance or replacement of the sensor it is recommended not to over tighten the sensor itself in fact it should be positioned close to the mechanical but not forced The electronic logic combined with sensor enables you to manage the alarm so visual acoustic or cause if necessary to stop the system 1 4 8 MINIMUM LEVEL The minimum level of grease in the tank is detected by a magnetic sensor 5 which detects the position taken during the work of the pump by a pivoting magnet M as shown in the figure The principle of operation of the magnetic sensor is to on off switch normally open At the time of starting the pump the system wiper rotates the magnet M pivoting The following two operating conditions may occur 1 if the grease level in the tank is higher than the minimum level the magnet pivoting M due to t
27. UNI EN ISO 9002 by the certification body named Det Norske Veritas Italia s r l company s mission is supply its customers with full assistance from the supply installation of dependable products down to on site maintenance CI APONI LUBRI FI CAZI ONE CENTRALI ZZATA s r l is a leading Italian company with over 35 years of experience that has gradually expanded its market and now serves several European customers MANUFACTURER S DATA Name CIAPONI LUBRIFICAZIONE CENTRALI ZZATA s r l Address Via Vittorio Alfieri 10 San Miniato Basso 56028 Pisa ITALIA Telephone 39 0571 42661 Fax 39 0571 42244 Web site WWW ciaponi it E mail address info ciaponi it Tax payer code VAT no 1701160480503 CUSTOMER SERVICE CIAPONI LUBRIFICAZIONE CENTRALI ZZATA s r l follows its customer directly by means of its post sale servicing To request further information or order spare parts it is possible to contact the Customer Service at the phone fax numbers listed above Part 1 General considerations Page 4 CIAPONI LUBRIFICAZIONE CENTRALIZZATA GENERAL WARNINGS All rights reserved Fourth edition J uly 2013 This Maintenance and Operation Manual has been prepared by CIAPONI LUBRIFICAZIONE CENTRALI ZZATA s r l and is supplied as is Therefore it cannot be copied reproduced circulated or transcribed in whole or in part without the written authorization of APONI LUBRI FI CAZIONE CENTRALI ZZATA
28. ZZATA s r l are designed to be used with lubrications with a maximum grade of NLGI 2 Use only compatible lubricants with NBR gaskets CIAPONI LUBRIFICAZIONE CENTRALIZZATA s r l supplies the system components that are already lubricated with NLGI 2 lubricant Family NLGI ASTM penetration at ue resse 09 jasa Semi fluid 400 430 greases Semi fluid 355 385 greases Mild greases 310 340 The table provides comparative data between NLGI National Lubricating Grease Institute and ASTM American Society for Testing Materials data only of the ranges used by the systems manufactured by CI APONI LUBRI FI CAZIONE CENTRALI ZZATA s r l For further information on technical data and safety measures see the Product Safety Sheet Directive 93 112 EEC related to the type of lubricant selected or supplied by the manufacturer Part 2 Operating manual Page 51 CIAPONI LUBRIFICAZIONE CENTRALIZZATA 2 4 0 START UP The operating procedure described below briefly describes the operations that have to be performed to start the system NB The following procedure should always be performed when e During the initial start up following installation e After every maintenance operation Ifthe system has not been in operation for a considerable amount of time 2 4 1 OPERATING PROCEDURE Make sure that e All the operations described in Chapter 1 6 0 ASSEMBLY have been performed e All
29. antees maximum sealing without the need of gaskets Code 096015 Straight fitting M6x1 conical 0 A NU TE NEA 1 096016 Straight fitting M8x1 conical 6 8 1 con 096017 Straight fitting M10x1 conical 10 1 con 096022 Straight fitting G1 8 G1 8 7 5 Code Description Code ipti O A 096018 90 fitting M6x1 conical 096020 90 fitting 10 1 conical 096023 90 fitting G1 8 M10x1 con G1 8 7 5 B e aon fe 09607890 ting 8 6 _ con 6 s Code Description 0 A 025030 90 fitting revolving 6 1 6 M6x1 8 025031 90 fitting revolving M8X1 6 M8x1con 8 025032 90 fitting revolving M10X1 6 10 1 con 8 00426 190 fitting revolving 61 8 1 8 igre Part 1 General considerations Page 28 Industry Raccordo ad innesto Click rapido Tubo 06 i gn A Premere Premere Figura 20 2 lt CIAPONI LUBRIFICAZIONE CENTRALIZZATA The quick fitting accelerates the assembly and disassembly of the system pipes Figure 19 shows the operations that have to be performed to quickly assemble and disassem
30. assa pulsante 1 4 NERO Pulsante 5 VIOLA Lampada spia luminosa max 15 W ra N a Q Em 77 1 GIALLO VERDE Terra J e varone Ss 3 MARRONE Fase 1 MARRONE 2 BLU The cable code 150056 derived from the A of the pump body must be connected to the electrical supply system and with the light button of the remote control device code 110001 The harness comes with about 600 mm of the sheath The CABLE 2P power sensor code 150050 derived from the S of the pump body must connected to the B sensor as for version 12 24 V DC VERSION WITHOUT TIMER OR WITH TIMER PAUSE WORK AND MINIMUM LEVEL 1 GIALLO VERDE Terra mm 2 BLU Neutro am 3 MARRONE Fase 1 MARRONE 2 BLU SS gt ff IG G The CABLE 2P power sensor code 150050 derived from the 5 of the pump body 15 what sends the signal to the minimum level Part 1 General considerations Page 42 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e VERSION WITH TIMER PAUSE SENSOR AND MINIMUM LEVEL A ROSSO 28 30 V DC i lt 2 Posizione vuota 3 ROSSO VERDE Massa pulsante
31. atore Motore Fuse 1 6A max lc NEP Neutro T 2 dM 7 Blu ES 5 Fa Terra BE 2 Giallo Verde 1 O 5 Test Enter 2 Presente sono nella versione con Minimo Livello Connettore S 7 Livello Blu Blu i Marrone Marrone 1 General considerations Page 45 CIAPONI Industry LUBRIFICAZIONE CENTRALIZZATA VERSION WITH TIMER PAUSE SENSOR Schema elettrico pompa 110 220V AC Timer Pausa Lavoro 24V DC Trasformatore 220 110V AC 24V DC Stabiliz Fase 4 b zatore 1 Diodo 54V DC T arrone Terra e Giallo I 4 2 Verde PE 5 5 Connettore Test L L M Enter Hosso Hosso Pulsante Posizione vuota 28 30V DC esterno Rosso Rosso Minimo Verde Verde Livello 1 N P pi RL 7 Mosfet 5 x L Marrone Lampada Viola Pa PP e
32. ble the pipes Quick fitting pipes can be used both as recyclable fittings and as pressure bushings for the primary and secondary pipes EXTENSIONS The tables that follow provide the codes of the straight and 90 extensions in brass which can be installed on the secondary pipes of the centralized lubrication system Straight extension 00460 M6x1 con M10x1 Straight extension M8x1 00499 10 1 7 12 18 M8x1 M10x1 con Straight extension M10x 00448 10 1 7 12 18 10 1 con M10x1 1 con Code Description 90 extension M6x1 00380 con M10x1 extension M8x1 00473 M8x1 M10x1 12 20 12 M10x1 2 90 extension 10 1 10 1 00430 10 1 7 12 20 12 10 1 Part 1 General considerations Page 29 CIAPONI LUBRIFICAZIONE CENTRALIZZATA The tecnical specifications of filling are Operating temperature From 30 C to 80 C Minimum pressure 0 99 bar Maximum pressure 150 bar Gas threads Compliance with 1507 1 BS 21 DIN 2999 Metric Conical threading Compliance with UNI 7707 1 4 6 TIMER The timer is located inside the pump housing in a waterproof area Its function is to automatically control the centralize
33. butor Code Pos Description 095020 Gasket initial element 095019 OB Gasket set dispensing element is useful to remember that that the number of coupled dispensers range between minimum of 3 and maximum of 10 The tightening torque of the tie rods must be equivalent to 6 Nm Newton per meter Part 1 General considerations Page 24 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e DOUBLING OF FLOW RATE The flow rate of each dispenser can be doubled by means of the internal connection of the two outputs In this case it sees only one of the two outputs of the dispenser For each lubrication cycle exit will be nominal flow rate twice that shown on the dispenser This operation with reference to Figure 19 is performed by unscrewing the fitting from the side of the written CX from the doser to whom one wants to double the flow phase A removing the threaded internal phase and then screwing the plug M10x1 phase C2 uF O if LIAPONI CIAPONI LIAPONI GAP ONJ 4 Figura 17 A IMPORTANT You cannot close both outputs on the same dispenser Part 1 General considerations Page 25 CIAPONI LUBRIFICAZIONE CENT
34. cuited and that is does not absorb a current above 7A Replace the reduction gear Contact the Customer Service Allow the pump to cool down for a few minutes and retry If the problem reoccurs contact the Customer Service Page 55 LUBRIFICA ZIONE CENTRALIZZATA Utilizzo del grasso in variazione di temperatura 80 X Distribuzione del grasso uniformemente su tutte le superfici CIAPONI LUBRIFICAZIONE CENTRALIZZATA Sede Via V Alfieri 10 56028 S Miniato Basso PI ITALY Tel 0039 0571 42661 Fax 0039 0571 42244 Sito internet www ciaponi it e mail info ciaponi it Cod Fis Partita n 1T01160480503 Costi con Impianto di Lubrificazione Centralizzata Riduzione dei costi Costi senza Impianto di Lubrificazione Centralizzata A salvaguardia dell ambiente
35. d lubrication system Technical specifications for models with Pause Operation timer 24 V DC Operating voltage 20 30V DC Maximim current load 5A Short circuit limitation 7A Current absorbed in stand by 30 mA Current absorbed during the cycle 50 mA except current motor Lamp power 15 W versions with remote control Operating temperature From 25 C to 70 C Storage temperature From 30 C to 80 C e Overload limitation e Polarity inversion Hardware protections Overheating e Overvoltage max 45 V Type of time memory Digital EEPROM Memory life Unlimited From 5 min to 12 hours through digital Pause time setting programming From 20 sec to 8 min through digital Working time setting programming WARNINGS Power the timer by thoroughly following the instructions provided in 4 1 0 WIRING DIAGRAM Do not power the timer with voltages above 35 V to prevent operating problems Part 1 General considerations 30 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e PAUSE WORKING CYCLE The control of the working cycle is completely entrusted to the digital programming of the timer After the pause time set the system begins a cycle of length equal to the time of scheduled work The working time must be programmed in such a way that the duration of the lubrication cycle is sufficient to supply all the bearing points connected to it The time nece
36. divide and dose the amount of lubricant among the points that have to be lubricated because Lubricant amount subject to wear secondary pipes distribute the lubricant to the fittings the replace the lubricators in the points subject to wear Automatic lubrication Manual lubrication The diagram in Figure 4 shows the operating cycle of a Figure 4 centralized lubrication system The system can be operated both in manual or automatic mode driven by the machine on which it is installed or by a control timer fitted inside the pump Each system is identified by means of a serial number stamped on the EC label under serial number year of manufacture Part 1 General considerations Page 9 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e serial number of the system must always be quoted when requesting technical information or ordering spare parts 1 4 0 TECHNICAL SPECIFICATIONS The paragraphs that follow list the technical specifications of each component of the system 1 4 1 ELECTROPUMP Figure 4 Electropump EUR 3 15 a piston pump driven by an eccentric cam designed to operate with grease or oil that can be used with a maximum of three pumping elements Figure 5 ref A B C connected to the lubrication centralized The housing of the pump is a compact monobloc element in plastic shaped in order to offer a full resistance to mechanical stresses The tank figure 5 ref D is transpa
37. e working time settings shown in the table The displayed value 15 stored as current value for Briefly press ENTER to confirm the L the display shown once more selected setting etter L The display turns off and is ready to run with the Press ENTER for 3 seconds new set parameters Remove cover B to access the timer The pump is ready to work and retighten screws ATTENTION Electropumps with control timers have the following default settings e PauseP 8 e Working time L 2 Part 2 Operating manual Page 49 CIAPONI LUBRIFICAZIONE CENTRALIZZATA Table with time settings e PAUSE e WORK settings for pause P settings for working times L 4 min sm Part 2 Operating manual Page 50 Industry 2 3 0 TANK FILLING CIAPONI LUBRIFICAZIONE CENTRALIZZATA The pump tank is filled by means of lubricator A maximum level tank Figura 24 2 3 1 LUBRIFICANTS Remove the cap from the lubricator and fill the tank up to the MAX marked with an adhesive label on the For information on the characteristics of lubricants see the following paragraph During the filling of the tank verify that the air in it is discharged by means of the vent Make sure that the vent located on the rear of the tank is not obstructed is useful to remember that systems manufactured by CIAPONI LUBRIFICAZIONE CENTRALI
38. gh The centralized lubrication system is downloaded with grease leakage After you restore the correct functioning of the system 15 necessary to verify that the indicator has returned to normal operating position In the event of overpressure circuit the grease falls into the pump from the pumping itself e Do not modify or remove the safety valve outside CIAPONI LUBRIFICAZIONE CENTRALI ZZATA s r l disclaims any liability for damage caused by tampering with the safety valve outside e n case of malfunction of the safety valve outside immediately contact Customer Service Figure 12 shows the version of the pump supplied as optional on request with manometer for measuring the pressure delivered The components shown are Pumping Washer 3 way shunt Manometer 90 fitting Manual lubricator pe cde X de le YS Cap Figura 12 Part 1 General considerations Page 17 CIAPONI LUBRIFICAZIONE CENTRALIZZATA 1 4 3 PIPES The main pipe is supplied in meters with recyclable bushing that have to be assembled during the installation of the system or optionally with pressure bushings The operations required to assemble recyclable bushings are described in paragraph 1 4 5 FITTINGS Even secondary pipes are supplied by meters All pipes are supplied with lubricant in order to prevent the formation of air bubbles The characteristics of the lubricant are specified in paragraph 2 3 1
39. he resistance offered by the grease to its progress tends to tilt with respect to the vertical 2 ifthe grease level in the tank is at the minimum level the magnet pivoting remains ina vertical position for effect of its own weight In the first case the magnetic sensor 15 ignores the presence of the magnet M pivoting the second case the magnetic sensor 5 detects the presence of the magnet pivoting and M indicates the minimum level is reached in the tank of the grease In the pump without timer and with timer pause the signal detected by the system must be managed to control the machine on which you installed the centralized lubrication system PLC In the pump with timer pause sensor the signal detected 15 processed by the timer which provides Figura 21 to instantly stop the centralized lubrication system signaling the end of grease to an indicator light Part 1 General considerations Page 33 CIAPONI LUBRIFICAZIONE CENTRALIZZATA The detection of the position of the magnet M begins with a delay of approximately 20 sec compared to the drive of the pump The detection system the minimum level is provided by the manufacturer as an optional and does not provide for adjustment The detection of the position of the magnet M begins with a delay of approximately 20 sec compared to the drive of the
40. layer pipe Hytrel elastomeric polyester compliant with the specifications listed standards ISO SAE DIN and UTAC Figura 14 The technical specifications for the secondary pipe are Dimensions 1 5 mm Operating temperature from 40 C to 80 C Minimum brust pressure at 20 C 150 bar Minimum bending radius 20 mm 1 4 4 DISPENSER Modular distributors or volumetric dispensers used are progressive dispensers with check valve They are made of a monobloc steel body containing small pistons in tempered steel which divide the flow ratebetween the outlets Elements are sealed by means of high resistance O Rings The progressive distributor can be supplied both assembled and disassembled The number of single dispensing elements which constitute a progressive distributor ranges from a minimum of 3 to a maximum of 10 Figura 15 Part 1 General considerations Page 19 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e SCREWTIE RODS FOR DISPENSENSERS screws UNI5931 TI E RODS Tie rods for 3 dispensing elements M6x65 Ago AA TIT I ttt Part 1 General considerations Page 20 CIAPONI LUBRIFICAZIONE CENTRALIZZATA The table that follows wich refers to figure 15 lists the codes for the necessary components of a progressive distributors Codes are also provided for the spare parts D ini ao LI rM
41. m Device minimum level From 30 C to 80 C 1 20r3 6 mm piston driven by eccentric cam Quick fitting for 6 mm pipe 2 4 8 liters with maximum and minimum level indicators Grease up to consistency grade NLGI 2 Oil 50 1000 cST 40 With lubricator A M10x1 UNI 7663 Rotating cylinder and windscreen wiper See pargraph 1 4 2 Pumping element Worm with helical wheel and DC shielded electric motor 24 V DC 12 V DC 24 V DC 0 12 1A 24 12 6 5A 22 12 DC 24 DC 110 220 V 50 Hz 1 0 2 1 65 None Timer or Timer and Sensor Optional for all versions TABLE B is shown for each model the empty weight of the pump in standard configuration with a single pump installed Table B capabilit 2 liters 3 3 kg m 5 al Part 1 General considerations Page 12 CIAPONI LUBRIFICAZIONE CENTRALIZZATA The following diagram shows for each model the maximum dimensions of pump expressed in mm Versione da 2 litri Versione da 4 litri Versione da 8 litri Lubrificante GRASSO Lubrificante GRASSO Lubrificante GRASSO Versione da 2 litri Versione da 4 litri Versione da 8 litri Lubrificante OLIO Lubrificante OLIO Lubrificante OLIO Figure 5 Part 1 General considerations Page 13 CIAPONI LUBRIFICAZIONE CENTRALIZZATA 1 4 2 PUMPING ELEMENT The pumping element
42. mp model Euro 3 type 150302 power supply 24 V DC serial number 038646 and lot of construction 11 06 month year Part 1 General considerations Page 6 CIAPONI LUBRIFICAZIONE CENTRALIZZATA DECLARATION OF CONFORMITY The Manufacturer CIAPONI LUBRIFI CAZI ONE CENTRALI ZZATA s r l Address Via Vittorio Alfieri 10 San Miniato Basso 56028 PISA ITALIA Telephone 39 0571 42661 Fax 39 0571 42244 Website WWW ciaponi it E mail address Info ciaponi it code VAT 1701160480503 Declare that the machine Model Elettropompa EUR 3 e complies with the requirements of Directive 2006 42 EC Annex section A on the approximation of the laws of Member States relating to machinery e complies with essential requirements of the Directives o 2004 108 EC Electromagnetic Compatibility in application of Directive 95 54 EEC Measure Radiated Electromagnetic Emissions and subsequent amendments o BT 2006 95 EC Low Voltage Also declares that laboratory tests were carried out in accordance with the following standards EN 61000 6 4 2002 10 EN 61000 6 2 2000 02 CEI 61000 3 2 2002 04 CEI EN 61000 3 3 1997 12 CEI EN 60204 1 1998 04 CEI EN 50178 1999 03 San Miniato Basso li July 2013 Il Legale Rappresentante Cibponi Lid 1 Part 1 General considerations Page 7 eoo CIAPONI LUBRIFICAZIONE CENTRA
43. one 1 s 5 Q 5 m Test IT Enter Presente sono nella versione con Minimo Livello Connettore S C MM M 2 Livello Blu Marrone C VERSION WITH TIMER PAUSE SENSOR Schema elettrico pompa 12 24V DC Connettore A Timer Pausa Sensore 12 24V DC Posizione vuota Stabiliz 12 24 DC dem si zatore Mosfet N 5 Diodo E m 5 12 24 Marrone Marrone oe e P i m 2 3 esterno L d Ed Viola Viola 6 Enter Lampada 7 esterna 2 gt 15W 12 24v DC pi _ Mosfet Minimo si Livello Sense Connettore S R Blu Blu 5 1 R 5 Marrone Marrone Marrone ee ee Presente sono nella versione 7 con Minimo Livello Part 1 General considerations Page 44 CIAPONI Industry LUBRIFICAZIONE CENTRALIZZATA 1 6 3 WIRING DIAGRAM VERSION 110 220 V DC VERSION WITHOUT TIMER OR WITH TIMER PAUSE WORK Schema elettrico pompa 110 220V AC Timer Pausa Lavoro 24V DC Trasformatore 220 110V AC 24V DC Ms Stabiliz Fase b z
44. or its components Furthermore the manufacturer shall not be responsible for damages originating from the use of non original spare parts or parts not certified by the manufacturer or for damages originating from the use of lubricants other than those listed Part 1 General considerations Page 8 CIAPONI LUBRIFICAZIONE CENTRALIZZATA 1 2 0 SAFETY An improper use of the centralized lubrication system may cause damage due an excessive or inadequate lubrication of the points to which it is connected It is always necessary to comply with accident prevention and environmental regulations in force in the country where the centralized lubrication system is used 1 3 0 DESCRIPTION OF THE SYSTEM Figure 3 shows a schematics of the centralized lubrication system in its basic configuration The system comprises the following units A Electropump with tank Main pipe C Multiple way dispenser D Secondary pipes Centralized lubrication systems significantly reduce the maintenance costs of the equipment on which they are installed lowering downtime for maintenance operations and increasing the life of lubricated components These systems also enable to reach all the points that require lubrication including those that are not accessible to Figure 3 operators If is active the pump conveys the lubricant into the main pipe of the pumping element to supply the dispenser Area with excessive which has to
45. peration principle of taking as reference distributor composed 3 dispensers The distribution and the flow rate to the various outputs is determined by the reciprocating movement of the pistons indicated with the letters A With the stretch in black 15 identifies the flow of pressurized Part 1 General considerations lubricant that determines the movement of the pistons The progressive distributor is powered by a pumping element of the pump EUR3
46. play LED 15 dali on correct 05 01 06 01 06 02 07 01 08 01 The motor The motor doesn t start when TEST is pressed The motor correctly The display LEDS alternate but the Faulty motor motor doesn t run The pump starts Faulty moto the greasing phase absorption but doesn t complete it immediately CIAPONI LUBRIFICAZIONE CENTRALIZZATA om eL 02 03 03 Unsuitable lubricant 0000 lubricant pumping unit is blocked ipes sive dispenser is The dispenser is not correctly to the bearing lubrication points voltage is not is not correctly connected to the timer is not working r or high output Part 3 Maintenance Instruction Replace the lubricant with a suitable one 04 Pumping unit blocked Disassemble the pumping element and clean the suction ducts 02 05 Worn pumping element piston Replace the pumping unit 02 06 The delivery valve of the Replace the pumping unit Check the status of the pipes and the connections to fittings pipes Replace worn Replace the dispenser or clean it Check that the dispensed amounts are compliant with those indicated in the system diagram Verify that the supply voltage ranges between 20V DC and 30V DC otherwise adjust the supply system Check the cables that connect the electric motor to the timer and restore connections Check that the motor is not short cir
47. ral considerations Page 35 MN CIAPONI LUBRIFICAZIONE CENTRALIZZATA e ELECTROPUMP It is advisable to observe the following recommendations e Do not install the submerged pump in liquids or on supports with high vibrations e Do not install the pump next heat sources or close to the electric equipment that could affect the correct operation of the control timer e Do not install the pump in areas with explosive or inflammable mixtures e Place electropump EUR in the position shown in N 2 FORI 99 the figure e Leave at least 100 mm from other equipment or obstacles that prevent access to the pump e Install the pump making sure that the lubricator for the tank filling and the control timer are easily accessible e Fix the pump to its support using the 0 9 mm holes and the 2 UNI 5931 8 8 screws Note it is also possible to use the STANDARD ROD Code 00610 available as optional FRONTALE on request Part 1 General considerations Page 36 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e PUMPING ELEMENT 3 The system is usually supplied with a single pumping element installed on outlet no 2 The figure shows the sequence of lt operations that need to be performed to install the pumping element on 4 _
48. rent polycarbonate molded for versions 2 liter and modular figure 5 ref E for versions 4 and 8 liters The filling of the tank takes place by means of a special lubricator figure 5 ref F situated the front part of the pump body for versions grease and through a screw cap figure 5 ref G on the top of the tank for oil versions Adhesive straps on the outside of the tank enable to easily identify the minimum and maximum levels Part 1 General considerations Page 10 CIAPONI LUBRIFICAZIONE CENTRALIZZATA The shaped roller system and windscreen wiper enable to eliminate air bubbles from the grease contained inside the tank thus ensuring a trouble free operation also at low temperatures The worm reduction gear with helical wheel and DC low voltage electric motor can be controlled directly or through the control timer figure 5 ref H The electric model EUR 3 can be supplied in various versions characterized by the supply voltage 12 to 24 V DC 110 220 V AC by the capacity of the tank 2 4 8 liters by the control system with or without timer programming by the presence or less of the sensor end of the cycle by the presence or less of the warning of minimum level of grease in the tank Electrical connections are made through wired systems Figure 5 ref TABLE A lists the codes of all the models of supply pumps Table A Pause Sensor Timer 2 liters 4 liters 8 liters 2 liters 4 liters 8 lite
49. rs 2 liters 4 liters 8 liters Voltage 150102 150104 150108 150152 150154 150158 150202 150204 150208 150252 150254 150258 150302 150304 150308 150352 150354 150358 160102 160104 160108 160152 160154 160158 160202 160204 160208 160252 160254 160258 160302 160304 160308 160352 160354 160358 160402 160404 160408 160452 160454 160458 160502 160504 160508 160552 160554 For versions with optional device MI NI MUM LEVEL code becomes 160558 160602 160604 160608 160652 5 150402 150404 150408 150452 150454 150458 150502 150504 150508 150552 150554 150558 150602 150604 150608 150652 150654 150658 160654 160658 15 E uon for all grease versions SI Eur for all oil versions SCIT E ess device press grease only grease version with tank 4 liters and supply voltage 24V Part 1 General considerations Page 11 Industry CIAPONI LUBRIFICAZIONE CENTRALIZZATA The technical specifications for electropump EUR 3 are listed below Operating temperature Number of outlets Pumping system Connection of main pipe Tank capacity Lubricant Tank filling System for the removal of air bubbles _ Capacity per outlet Reduction gear e Rated voltage e Rated absorption e Max pickup absorption e Speed Power supply e Rated absorption 220V AC 110V AC Protection class Control syste
50. ss to the fitting of pipes For models with sensor place the dispenser in a position that allows the cables to be easily connected to the electropump the dispenser to the frame or crossbeams so that it is possible to reach the lubricating points of the bearing To progressively fix the dispenser to its support use holes A and B located on the initial and final sections of the assembled Ciaponi CIAPONI Tighten the sensor as shown the figure MAIN AND SECONDARY PI PES e Cut the pipes to measure at a straight angle using a cutter or a shearing unit e Tagliare le tubazioni a misura con taglio ad angolo retto utilizzare un taglierino con ci x 0259 0 10 0 05 e e Only for the version with Pause control timer Sensor Sensor code 095032 must be installed only on 0 25 cm dispensers Remove the screw cap with metal gasket A Press the small piston until it reaches the limit switch use a plug with a diameter of sistema di taglio a cesoia NB the pipe length should be calculated taking into account the minimum bending radius and the additional length required for the pipes fixed to mobile parts Fix
51. ssary for the completion of a lubrication cycle can be determined by detaching the secondary pipe from any output of the progressive distributor and measuring the time elapsed between two successive deliveries In case of difficulty in the determination of working time contact Customer Service e PAUSE SENSOR WORKING CYCLE cycle control is assigned only to the Timer for programming the pause time After the pause time set the system begins the stage of lubrication proximity sensor or switch to induction installed on the progressive distributor reads the positions of the beginning and end of the cycle automatically stopping the operation of the pump In case of failure of plant operation the Timer after 10 minutes from the drive it shall stop its operation A control device remote cod 110001 consisting of an illuminated push button installed on the control panel of the machine or vehicle allowing the drive and verify the operation of the lubrication system 7 In case of difficulty in the determination of pause time contact Customer Service 1 4 7 SENSOR CONTROL WORKING DISTRIBUTORS e SENSOR CODE 095032 FOR AUTOMOTIVE APPLICATIONS The sensor code 095032 normally used in the automotive sector works as a button Its output is an internal contact It is used
52. sterna ee Presente sono nella versione y max 15W con Minimo Livello 2 Sensore Connettore S Blu 5 S Marrone Marrone Part 1 General considerations Page 46 CIAPONI LUBRIFICAZIONE CENTRALIZZATA PART 2 OPERATING MANUAL 2 1 0 COMANDS The table that follows describes the command and control devices of centralized lubrication systems with Pause Operation timer and Pause Sensor timer The figure shows the devices installed on the Timer EN 2 3 The pump of versions without timer are electrically powered by the system that drives them In this case start and control instructions are described along with the management and control instructions of the machine where the system 15 installed 1 Display e t displays the parameters that have been set during the time setting procedure display LEDs turn on in sequence during ordinary operation 2 Led display This LED turns on when the lubrication system is electrically powered 3 Button TEST To access the timer it is sufficient to slightly press it next to Push If it Is pressed during ordinary operation it starts the set working cycle after performing a self diagnostic check At the end of the working cycle the timer returns to the Automatic mode If it is pressed during the timer programming it enables to scroll the options Button ENTER If it is pressed for 3 seconds i
53. ston B to the left allows the dispensing exit 3 and predisposes the lubricant under pressure to the shift of the piston STEP 6 The shift of the piston to the left allows the delivery junction 5 and prepares the lubricant under pressure to the shift of the piston A has been completed a lubrication cycle of the progressive distributor in question Part 1 General considerations Page 23 CIAPONI LUBRIFICAZIONE CENTRALIZZATA e ASSEMBLY The dispenser must be assembled as shown in Figure 16 The initial element A dispensers B with the selected capacities and the end element C must be paired correctly positioning the O ring seal for each item OE D Tiranti Esempio di distributore composto da n 3 elementi dosatori Elemento iniziale Elementi Br num min 3 num max 10 Elemento Schema di assemblaggio Figura 16 In the table below we list the codes of the gaskets needed to assemble a progressive distri
54. t Consists of all the information of product presentation describing the purpose and scope the technical characteristics of the main components and the different versions as well as the directions for the correct installation of centralized lubrication Part 2 User Manual Consists of all the general information is the entire set of information necessary for the operation of the plant and for correct control and use of the same Part 3 Instruction for maintenance Consists of all the information needed to adequately perform some simple maintenance In this part there are also some very useful information in the event of a malfunction Part 4 Spare parts Consists of all the information necessary for the management of spare parts SAFETY STANDARDS APPLI ED Centralized lubrication systems are designed manufactured and installed in accordance with the requirements set forth in Directive 2006 42 EC Therefore for the purposes of the EC marking implant that is placed in the position shown in Figure 1 adhesive is applied to a metal plate as shown in CIAPONI sri figure 2 and in which are contained the following 56028 sminiato ITALY 3 150302 information Voltage 24 3 Press max 250 bar Manufacturer s data Series 038646 CE Produz 11 06 e Figura 1 Figura 2 Serial number Year of manufacture e Power supply data Example of a metal plate for EC marking of a pu
55. t starts the digital programming procedure If it is pressed briefly during the programming mode it enables to change the P pause and L working values Part 2 Operating manual Page 47 CIAPONI LUBRIFICAZIONE CENTRALIZZATA A remote control system is available as optional for systems with Pause Sensor timer This must be installed next to the control panel of the vehicle or the machine where the system is installed Luminous This indicator turns on when the centralized lubrication system Is indicator remote powered It remains on for a few seconds until the timer has control device completed the initial check and then turns off It blinks when the pump is running It turns on when there is no grease the tank or if a problem occurs on the system If pressed during ordinary operation it starts a work cycle after performing a self diagnostic test Upon completion of the cycle the timer returns to the Automatic mode 2 2 0 TIMER PROGRAMMI NG The sections that follow summarize the operations that need to be performed to digitally program the control timer It 15 useful to remember that If a power outage occurs the timer saves the internal data in a digital memory that has no expiry As soon as power is restored the timer reloads the saved data and starts counting the time from the point and status in which it had interrupted its operation 1 Display 2 Led display
56. the Pause and Pause Operation times have been set for versions with control timer e The lubricant level in the pump tank is above the minimum level Disconnect one or more secondary pipes Verify that the lubricant reaches the from the bearing lubrication points bearing Press the manual Start button TEST The pump performs one cycle points of the bearings from which the pipes correctly have been disconnected Reconnect the pipes to the bearing system is set in Automatic mode lubrication points Repeat the operation described above until the lubricant reaches all the lubrication The lubricant dispensing system is running ATTENTION if the system is not operating correctly see Chapter 3 3 0 ANOMALI ES Part 2 Operating manual Page 52 CIAPONI LUBRIFICAZIONE CENTRALIZZATA PART 3 MAINTENANCE INSTRUCTION 3 1 0 MAINTENANCE INSTRUCTION This paragraph provides essential information to allow maintenance technicians to perform ordinary maintenance operation in full safety Before performing any maintenance operation operators should remember to That the system is not running That the electropump has been disconnected from the power supply That the disconnection switch upstream from the electric cubicle has been All the measures referred to in current accident prevention laws and specifically 3 2 0 SCHEDULED MAINTENANCE Due to simplicity of design robustness and reliability of
57. the components used LUBRI FI CAZI ONE CENTRALI ZZATA s r l recommends only a limited number of inspections and scheduled maintenance operations The table that follows lists the checks that have to be performed periodically along with the frequency and type of operation that the technician must perform to guarantee the efficiency of the system in time CHECK FREQUENCY OPERATI ON Tightening of components After the first 500 Check that all components have been hours correctly tightened Pipe fixing After the first 500 Check that the fittings have been installed hours Check that machine parts have been Every 1500 hours correctly installed Operation of the Every 6 months Check the operation of the electropump electropump with button Test Tank level Refill the lubricant in the tank Filling filter Every 2 fills Check replace see following paragraph Part 3 Maintenance Instruction Page 53 CIAPONI LUBRIFICAZIONE CENTRALIZZATA 3 2 1 FILTER REPLACEMENT ONLY GREASE VERSION To service the filling filter of the tank it is necessary to remove cap A the lubricator and filter Inspect the filter and clean it with compressed air if necessary If the filter is still dirty after being cleaned replace it Reassemble filter lubricator and cap A Tighten the lubricator B with a maximum torque of 6 Nm Figura 2

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