lubrication pump pmp - smøreteknikk · no_pmp_ eng 4-2013 lubrication pump pmp operating...
TRANSCRIPT
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 1 of 23 NO_PMP_ ENG 4-2013
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Lubricat ion pump PMP
Opera t i ng Ins t ruc t i on
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 2 of 23 NO_PMP_ ENG 4-2013
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CONTENT 1 APPLICATION ................................................................................................................................. 3
2 DESCRIPTION ................................................................................................................................ 3
3 OPERATION .................................................................................................................................... 5
4 TECHNICAL DATA .......................................................................................................................... 6
5 IDENTIFICATION CODE OF LUBRICATION PUMP PMP ............................................................. 7
6 LUBRICATION PUMP PMP – FOR GREASE ................................................................................ 8
7 LUBRICATION PUMP PMP – FOR OIL .......................................................................................... 9
8 LUBRICATION PUMP PMP – FOR GREASE, OIL WITH GSM MODUL ..................................... 10
9 INSTALLATION, SERVICE AND MAINTENANCE ....................................................................... 11
10 WIRING DIAGRAM.................................................................................................................... 11
10.1 CONNECTOR – SUPPLY VOLTAGE ................................................................................... 11
10.2 CONNECTOR - ALARM ........................................................................................................ 12
10.3 CONNECTOR – CYCLES READER ..................................................................................... 12
10.4 CONNECTOR – EXTERNAL ADDITIONAL LUBRICATION ................................................ 12
11 SETTING OF LUBRICANT DOSE REGULATION UNIT .......................................................... 13
12 BASIC SETTING ....................................................................................................................... 14
13 NUMBER OF SENSORS SETTINGS ....................................................................................... 14
14 CONTROL TIMER PROGRAMMING ........................................................................................ 15
14.1 LUBRICATION TIME – PAUSE TIME ................................................................................... 15
14.2 NUMBER OF CYCLES – PAUSE TIME ................................................................................ 15
15 GSM MODULE .......................................................................................................................... 16
15.1 DESCRIPTION ...................................................................................................................... 16
15.2 BEFORE ASSEMBLING ....................................................................................................... 17
15.3 PROGRAMMING ................................................................................................................... 17
15.4 ASSEMBLY AND START-UP ................................................................................................ 17
15.5 TECHNICAL PARAMETERS ................................................................................................ 17
16 LUBRICATION PUMP ACCESSORIES .................................................................................... 18
17 FAILURE REPORTS AND THEIR ELIMINATION .................................................................... 22
17.1 A LIST OF MOST FREQUENT FAILURES ........................................................................... 22
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 3 of 23 NO_PMP_ ENG 4-2013
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1 APPLICATION
The PMP lubrication pump is used as a pressure lubricant source for central lubricating systems with
progressive distributor types BVA, PRA and PRB, for permanent, regular lubrication of various
machines and equipment. Furthermore, they can be applied as a pressure source for central
lubrication of mobile machines and equipment, mainly for the chassis of lorries, buses, trolley-buses,
semi-trailers, trailers, building machines, agriculture and forestry equipment. PMP lubrication pumps
are recommended for use in small to medium size lubrication circuits with up to 100 lubricated points.
With respect to a variable number of outlets, from 1 to 3, the lubrication pumps of the PMP series may
be also used as a direct source of pressure lubricant (multi-outlet lubrication pump).
The PMP lubrication pumps are supplied in both oil and grease versions with a variant lubricant tank
volume of 2, 4, 6 or 8 litres with tanks made of organic glass, and also 6, 8 and 12 litres with metal
tanks. The number of outlets is selectable from of 1 to 3. Nominal doses can be adjusted from 0,8 to
3.8 cm3/min or fix dose (2.5 and 3.5 cm
3/min). The working units are optionally supplied with safety
(by-pass) valve and pressure gauge.
Electric motor is supplied in version 12V DC and 24V DC, with protection to IP 65. Supply voltage of
the lubrication pump is selectable 12V DC, 24V DC, 115V AC and 230V AC, with a built-in toroidal
transformer whose output voltage after rectification is 24V DC - 2.7 A. Upon customer’s request, the
PMP lubrication pumps can be supplied without a control automatic system or equipped with a built-in
control automatic system, controlling the operation of the lubrication pump and the entire lubrication
circuit with progressive distributors.
The control automatic system is supplied by default in a version for connecting a single contactless
sensor (on the progressive distributor), or alternatively in a version for connecting up to three
contactless sensors at the same time, allowing to control the operation of up to three mutually
independent lines of a lubrication circuit with progressive distributors. The control display of the
automatic system can be protected by a strong cover from organic glass.
The lubrication pump can also be equipped with external (remote) triggering of the additional
lubrication cycle, i.e. a manually entered command to perform one lubrication system in addition to the
set operation programme.
For applications requiring on-line monitoring of operation of a lubrication circuit (or multiple circuits),
the lubrication pump is supplied in a version with a programmable GSM module which communicates
with user’s mobile phone using SMS. The messages sent include messages about reaching the
minimum lubrication level in the lubrication pump tank, error messages from lubrication checks
performed by the contactless sensor (with reporting sensor identification, i.e. identification of the
lubrication circuit line), information about motohours worked, and notification about supply voltage
failure (after voltage restoration).
2 DESCRIPTION
The main part of the lubrication pump is the pump body from aluminium alloy and a cam mechanism
that allows fitting the lubrication pump with 1 to 3 dosing units. Each dosing unit has one outlet with
G1/4“ female thread for an outlet threaded joint for a pipe with 6, 8 or 10 mm external diameter. A
lidded lubrication tank is placed vertically on the pump body. For better grease pumping, the tanks are
fitted with a scraper blade. The cam mechanism electromotor is located in the lower part of the pump
body and it is protected by a casing that includes in the front side a plastic control panel with a display
and electronics of the control unit for automatic operation of the lubrication pump and lubrication circuit
with progressive distributors. The left side of the casing can be equipped with up to four connectors.
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 4 of 23 NO_PMP_ ENG 4-2013
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The connector labelled POWER is designed to lead the supply voltage of 24V DC (12V DC, 115V AC,
230V AC). The ALARM connector is designed as the output for signalling the minimum level and for
the E1, E2, E3 alarm – cycle sensor control. The CYCLE connector is designed for connecting the
contactless sensor of the progressive distributor. In the lubrication pump version for connecting
multiple contactless sensors, the CYCLE connector is an 8-pin version and looks different. The
EXTERNAL connector, is designed for connecting the external button of additional lubrication. Under
the supply connector (POWER) there is a fuse case with a T 2.5A fuse for all voltages. In design of
more sensors there is a covered 3-way switch, made for switching the number of sensors
A lubricating nipple for lubricant filling is located at the front of the pump body. For stationary
application of the lubrication pump, a G1/4“ tapped hole of the lubricating nipple for direct connection
can be used for permanent remote lubricant filling. The body is fitted in the rear with a block with two
holes for M8 bolts for attaching the pump to the side of a machine or device.
The control panel of compactly built-in control automatic system with a display is equipped with
buttons, LED indicators and a double seven-segment LED display.
1. The START/ENT button is designed for starting the lubrication pump in the
additionallubrication cycle. In the mode for setting the lubrication operation and pause times, it
is used for the transition to time value entry mode. At the next push, the set time values are
saved in memory and the programme returns to the value setting selection mode.
2. The STOP/ESC button is used to interrupt the lubrication cycle, to reset the time settings
without changing these values, and to return from the setting mode to lubrication programme
operation. The button is also used to reset the alarm function (resetting the red light signalling
the minimum level and the E1 E2, E3alarm signalling not achieving the required number of
cycles).
3. The "opposing arrows" selection buttons are used to change to the value-browsing mode and
to change these values.
4. The operation LED indicator "sun" signals the mode of lubrication operation time or the setting
thereof. In the NUMBER OF CYCLES / PAUSE programme and its setting, the control
maximum time is determined for achieving the selected number of cycles.
5. The pause LED indicator "moon" signals the pause mode or the setting thereof.
6. The cycle LED indicator "arrow" signals that the device runs in the NUMBER OF
CYCLES/PAUSE programme.
7. The hours LED indicator "hour" signals the hours set or being set.
8. The minutes LED indicator "min" signals the minutes set or being set.
9. The seconds LED indicator "sec" signals the seconds set or being set.
10. The alarm LED indicator "drop" signals lack of lubricant in the tank.
11. The LED display shows the time values set or being set, the number of cycles and the alarm
symbol – E1 E2, E3.
TriboTec spol. s r.o.
Košuličova 4 www.tribot
619 00 Brno tel: +420
Czech Republic
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Pic. No. 1 Keyboard of contro
The control automatic system is
lubrication cycle course and the se
electric power source. After the po
the programme continues from
meaningless (outside the valid val
voltage oscillation may occur, ca
meaningless values). This conditi
values are reread from memory.
3 OPERATION
The lubrication pump works on t
mechanism that controls the pisto
piston is drawn out of the pumpin
unit's operation cylinder; when
follows; when it is drawn in, lubric
lubrication pump's outlet. As the c
grease from the tank wall and mo
the lubrication pump operation.
The control unit electronics contro
programme is set automatically ac
panel a specific value of the lubric
circuit with progressive distributors
1
4
5
6
3 10
11
Lubrication pump
Operating Instruction
.tribotec.cz, [email protected]
543 425 611
NO_PMP_ ENG
ontrol unit
m is provided with read-only memory that stores inf
the set time values even after disconnecting the lubric
he power supply is restored, the stored values are rea
from the point of interruption. If the respective va
lid values range), it is reset automatically. When the d
ur, causing the control unit programme to "hang" (
ondition is repaired after max. 2 seconds by autom
on the principle of a piston pump. The electromoto
pistons of pumping units in a direct reciprocating mo
umping unit into the pump body, there ensues negat
en it is fully drawn out, the suction duct opens an
lubricant is pressed out and proceeds through a non
the central shaft and cam rotate, the scraper blade ro
d moving it to the suction zone. Its movement allows
ontrol the pump operation in two independent program
ally according to connection type. The operator sets on
lubrication and pause times and the number of cycle
butors.
1. START/ENTbu
2. STOP/ESCbu
3. Choicebutton
4. LED operation
5. LED pauseind
6. LED cycleind
7. LED hourindi
8. LED minutein
9. LED second i
10. LED MIN. leve
11. Display
7
8
9
2
3
mp PMP
page 5 of 23 ENG 4-2013
es information about the
lubrication pump from an
re read from memory and
ive value in memory is
the device is turned on,
ang" (the display shows
utomatic reset and time
romotor powers the cam
ng movement. When the
negative pressure in the
ns and the suction itself
a non-return valve to the
ade rotates too, scraping
llows visual inspection of
rogrammes. The relevant
ets on the plastic control
f cycles of the lubrication
button
button
utton
rationindicator
seindicator
leindicator
rindicator
uteindicator
ond indicator
level alarm indicator
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 6 of 23 NO_PMP_ ENG 4-2013
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4 TECHNICAL DATA
Maximum working pressure 350 bar
Operating pressure 280 bar
Nominal fixed dose 2.5; 3.5cm3/min./ outlet
Nominal adjustable dose 0.8 ÷ 3.8 cm3/min./ outlet
Lubricant tank capacity 2; 4; 6; 8 dm3 (organic glass)
6; 8; 12 dm3 (metal)
Pause time setting 1 to 59 min.; 1 min. increment
1 to 99 hours; 1 hour increment
Lubrication time setting 1 to 59 sec.; 1 sec. increment
1 to 99 min.; 1 min. increment
Number of cycles setting 1 to 99
Setting the control time of cycles 1 to 99 min.
Number of cycles readers 0 to 3
Number of outlets 1 to 3
Outlet threaded joint G1/4“, for tube outside dia. 6, 8, 10 mm
Electromotor 24 V DC, 28 W, 1.1 A, IP 65
12 V DC, 28 W, 2.2 A, IP 65
Supply voltage of lubrication pump
24 V DC - 1.1 A; 12 V DC - 2.2 A
115 V AC - 0.26 A, 60 Hz
230 V AC - 0.13 A, 50 Hz
Supply voltage of external signalling max. 30 V - 1 A
Lubricant grease max. NLGI - 2
oil min. 50 mm2 . s-1
Working environment temperature -25 to 80 0C
Weight 5.8 kg (depending on execution)
Table No. 1 Technical data lubrication pump PMP
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 7 of 23 NO_PMP_ ENG 4-2013
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5 IDENTIFICATION CODE OF LUBRICATION PUMP PMP
Pic. No. 2 Catalogue page of lubrication pump PMP
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 8 of 23 NO_PMP_ ENG 4-2013
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6 LUBRICATION PUMP PMP – FOR GREASE
Pic. No. 3 Lubrication pump PMP – for grease
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 9 of 23 NO_PMP_ ENG 4-2013
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7 LUBRICATION PUMP PMP – FOR OIL
Pic.No. 4 Lubrication pump PMP – for oil
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 10 of 23 NO_PMP_ ENG 4-2013
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8 LUBRICATION PUMP PMP – FOR GREASE, OIL WITH GSM MODUL
Pic.No. 5 Lubrication pump PMP – GSM module
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 11 of 23 NO_PMP_ ENG 4-2013
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9 INSTALLATION, SERVICE AND MAINTENANCE
The lubrication pump is mounted in a horizontal position through two anchor holes with M8 bolts.
Version with grease follower plate can be mounted in any position. A drill template, supplied with the
lubrication pump, makes the mounting easier. All corresponding connectors of the lubrication pump
are connected according to the wiring scheme. The pump tank is filled with a prescribed clean
lubricant through the lubricating nipple or from above, after opening the tank lid (of the metal tank). In
the oil version, the lubrication pump is filled from above through the filling hole with a oil-strainer.
Version with follower plate must be filled by coupling. The lubrication pump may not be refilled with
impure or otherwise debased lubricant. The required lubrication cycle is set on the plastic push-button
panel: 1. lubrication time – pause time or 2. number of cycles – pause time. The pump is switched on
by turning on the switch of the machine or the switch of the utility vehicle's drive and it is observed,
whether it runs smoothly and regularly. The lubricant that remained inside the lubrication pump after
the pressure test as preservative is pumped out. If the lubricant flows from the outlet regularly and
without air bubbles, the outlet is closed by attaching it to the lubrication circuit pipe.
The dose is smoothly regulated independently for each adjustable working unit (outlet) by an
adjustable shaft with a safety nut. Maximum dose is set by manufacturer.
Besides the lubricant refilling in the tank, the lubrication pump requires no other maintenance.
The lubricant has to be refilled particularly if the empty tank red light starts flashing on the
plastic push-button panel.
The control automatics system must not be exposed to mechanic action (impacts, shocks). Cleaning
of the surface maybe performed only when using a soft cloth soaked in a small amount of neutral
detergent. If an organic solvent is used, e.g. petrol, or a detergent on the basis of alcohol, the plastic
maybe damaged. If you identify some damage (breaking, fogging of the door, the smell of burnt
matter, distortion or pulling of the cable from the bushing) an immediate repair is necessary. Repairs
maybe performed only by a person who has a specialised electrical qualification, while it is necessary
to observe all applicable safety standards. It is forbidden to tinker with the machine in any way during
the warranty period (unscrewing the cover, change of the connection etc.) Unauthorized intervention in
the equipment is a sufficient reason to make the quality warranty void.
10 WIRING DIAGRAM
10.1 CONNECTOR – SUPPLY VOLTAGE
Pic.No. 6 Wiring diagram of supply voltage connector 12, 24, 115 a 230V
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 12 of 23 NO_PMP_ ENG 4-2013
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10.2 CONNECTOR - ALARM
Pic.No. 7 Wiring diagram of alarm connector
10.3 CONNECTOR – CYCLES READER
A) 1 reader wiring
Pic.No. 8 Wiring diagram of connector for 1 reader
B) 1 to 3 readers wiring
Pic.No. 9 Scheme of connection of more contactless readers
10.4 CONNECTOR – EXTERNAL ADDITIONAL LUBRICATION
Pic.No. 10 Wiring diagram of external additional lubrication connector
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 13 of 23 NO_PMP_ ENG 4-2013
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11 SETTING OF LUBRICANT DOSE REGULATION UNIT
Graph No. 1 Process of lubricant dose on a length of screwing off the shaft
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 14 of 23 NO_PMP_ ENG 4-2013
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12 BASIC SETTING
Pre-set values from the manufacturer are following:
Maximum dose 2.5; 3.5; 3.8 cm3/ min
Safety valve pressure 300 bar
Lubrication time settings – minutes 1 min
Lubrication time settings– seconds 0 sec
Pause time settings – hours 0 hrs
Pause time settings – minutes 1 min
Number of cycles settings 3 cycles
Time for cycles control settings – alarm „E1“ („E2“, „E3“) 1 min
Table. No. 2 Basic setting of PMP pump
Note. From the manufacturer comes standard adjustable safety valve pressure BZV
13 NUMBER OF SENSORS SETTINGS
This part is intended for a configuration of lubrication pump with more cycles sensors (with 2 or 3
sensors). The control timer is not able to analyse itself the number of connected controlling contactless
sensors. Therefore is necessary to set the number of connected sensors before the first start. Under
the ALARM connector there is a plastic cork (1). This cork is necessary to unscrew by a big and flat
screw-driver. After uncovering this cork a 3-way switch (2) will shown, on which we set the number of
contactless sensors.
Pic No. 11 PMP number of sensors settingPic No.12 Place for 3-way switch
It is possible to set 3 levels on the 3-way switch. These levels correspond with number of sensors.
Each sensor level is shown in a picture No. 13.
Pic.No. 13 Showing the switches of contactless sensors
1
2
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 15 of 23 NO_PMP_ ENG 4-2013
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14 CONTROL TIMER PROGRAMMING
14.1 LUBRICATION TIME – PAUSE TIME
This programme is used for circuits with progressive distributors without signalling or with optical
signalling of operation (signalling pin). This connection programme allows you to determine the
lubrication time, i.e. the period of time in which the lubrication pump operates, and the pause time, i.e.
the period of time in which the pump rests.
The scheme of programming is in app. No. 1, page No. 2.
14.2 NUMBER OF CYCLES – PAUSE TIME
This programme is used for circuits with progressive distributors, at least one of which (with a
maximum of three) is equipped with electric operation signalling (contactless sensor). In this
programme, you can determine the pause time, i.e. the period of time in which the pump rests,
similarly to programme no.1. The lubrication time is determined by the optional number of lubrication
cycles (from 1 to 99).
The number of cycles is given by the number of switches of the contactless control sensor located on
one of the progressive distributors. The pump operates continuously until the set number of cycles is
finished. To inspect the lubrication circuit operation, there is also set a maximum time in which the set
number (1 to 99) of switches of the contactless control switch shall be made. If the set number of
switches of the contactless control switch (cycles) is not made in this time period, i.e. any of the
lubrication cycles is not completed, E1, E2, or E3 is displayed on the display based on which sensor
failed to send the electric signal indicating uncompleted lubrication in the cycles programme.
The E1, E2, E3 alarm signalling can also be connected via the ALARM connector on the lubrication
pump body to external light (or sound) signalling.
This E1, E2, E3 alarm signalling operates until the STOP/ESC button is pressed on the control
automatic system panel. If the fault in the lubrication circuit is not removed, the failure will be signalled
again after the following unsuccessful lubrication (pump operation) or after an uncompleted lubrication
cycle.
During this signalling of uncompleted lubrication in the cycles mode, the lubrication pump continues to
operate, lubrication (pump operation) is terminated when the set maximum time for cycles operation is
reached (i.e. the time till E1, E2, E3 alarm), followed by the pause time after which lubrication in the
cycles mode is performed again. If lubrication in the cycles mode fails again (is not completed),
lubrication is again terminated after the set time till E1, E2, E3 alarm (maximum time for cycle
operation), and the lubrication pump switches to a pause again.
The control automatic system is programmed to automatically switch to the NUMBER OF CYCLES –
PAUSE TIME programme when the contactless sensor is connected via the CYCLE connector on the
lubrication pump body.
When the contactless switch is disconnected, the automatic system switches again to the
LUBRICATION TIME – PAUSE TIME programme, and lubrication time is automatically set to the
maximum time for cycles operation, i.e. the time till E1, E2, E3 alarm (set in minutes, 0 seconds). In
this case, if the contactless switch is no longer used, it is recommended to make a new setting,
optimal for the LUBRICATION TIME – PAUSE TIME mode.
For proper functioning in the NUMBER OF CYCLES – PAUSE TIME mode it is necessary to set the
maximum time during which the selected number of cycles (1 to 99) is to be achieved, i.e. the time till
triggering the E1, E2, E3 alarm, so that all lubrication cycles are sure to finish before this set time. This
time till triggering the E1, E2, E3 alarm is recommended to be by about 50 % longer than the time
really necessary for proper operation of all selected lubrication cycles. The real time of lubrication is
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 16 of 23 NO_PMP_ ENG 4-2013
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individual for individual lubrication circuits, depending on the lubrication circuit range, number of
progressive distributors, selected piping, total length of piping, lubricant, and operating conditions of
the system. The real time of lubrication (pump operation) must be measured when the lubrication
circuit is installed and put into operation.
All newly selected and read values in the control automatic system’s programme are active only after
the currently running mode, or time, ends, as newly read values.
Alternatively, the lubrication time start can be initiated with the START/ENT button, and when it ends,
the newly set pause time will count down.
If the lubrication pump is equipped with signalling of minimum level of lubricant in the tank, the
lubricant level decrease below the minimum level is signalled on the display of the control automatic
system with a blinking red LED light. Minimum level signalling can be connected via the ALARM
connector on the lubrication pump body to external light (or sound) signalling. This doesn´t apply with
signalling level by ultrasonic switch UB 2000, which has separate connector (only for metal tank 8L
and 12L).This external signal is not interrupted, as opposed to the signalling LED light on the panel.
After refilling the tank with lubricant, the minimum level alarm signalling must be cancelled by pressing
the STOP/ESC button on the automatic system panel (alarm reset).
An additional lubrication cycle can be performed at any time in the pause mode using the START/END
button. The pause time is reset and when the set time of lubrication (programme no. 1) expires, or
when the determined number of cycles is reached (programme no. 2), the set pause time is counted
down again, and the control automatic system continues in the selected programme. It is
recommended to use the additional lubrication cycle after refilling the tank with lubricant, if its level
decreased below the minimum level and the alarm was triggered (minimum level signalling), in case of
repairing the lubrication circuit after the cycles control sensor alarm, or after long-term downtime of the
machine. When needed, additional lubrication can be stopped by pressing the ESC/STOP button
before the contactless switch sends the pulse indicating the completion of the additional lubrication
cycle (programme no. 2).
The scheme of programming is in app. No. 1, page No. 3
15 GSM MODULE
15.1 DESCRIPTION
The GSM module is an extension to the lubricating machine PMP. The module is powered from the
automatic system of the lubrication machine and therefore it can only be used only in combination with
this automatic system. The GSM is a device that immediately signals failure statuses of the lubrication
machine that occur during the operation of the lubrication machine. The list of failure statuses is
described in table 4 on page 22. It is even possible to check the lubrication machine via the GSM
module. This check is carried out by phoning to a phone number of the SIM card. If the lubrication
machine is switched on, the GSM module terminates the incoming phone call and subsequently sends
back an SMS information message about the status of the lubrication machine. The delivered
message includes the name of the lubrication machine, the time of machine lubrication in hours (motor
hours) and an identification number from the manufacturer. The identification number is also depicted
on the back side of the automatic system. The GSM module does not respond to a phone call from
another telephone number.
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 17 of 23 NO_PMP_ ENG 4-2013
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15.2 BEFORE ASSEMBLING
Before the GSM module is installed it is necessary to insert the SIM card into a black box. The cover
of the box is attached by four screws. After the screws are removed the SIM card is inserted in the
holder. Make sure to position the SIM card correctly in the holder. The GSM module is not blocked and
therefore it is possible to use a SIM card from any operator. No active PIN code may be on the used
SIM card. The package of the GSM module includes an antenna for direct connecting to the SMA
connector. If installed in a place with a bad signal, it is possible to order an antenna with a cable (order
code 625 900 180 050).
15.3 PROGRAMMING
Programming is performed through a data cable, which is ordered separately (order code 8550538). A
data programming cable is delivered with an installation CD, on which the control software
(PMP_config.exe) is recorded. For programming it is necessary to connect a lubrication machine PMP
by a programming cable from the panel connector GSM to PC over a serial port RS 232 and have the
file PMP_config.exe running. The programming is intuitive and simple. A detailed overview of
programming is given in Annex no. 2. The program enables setting of the phone number for
sending of SMS messages, the own name of the lubrication machine and the number of motor hours.
(Motor hours mean how many hours the electromotor of the machine has been running. This means
the time for which the machine has been lubricated. This information does not count in the time of
pauses). After required parameters have been set and saved the machine is adjusted and ready to be
used.
15.4 ASSEMBLY AND START-UP
The GSM device of the lubrication machine runs independently of the automatic system of the
lubrication machine. The GSM module with a holder is fitted onto two anchoring screws M8. The
holder with the GSM module is inserted between the supporting surface of the lubrication machine and
the fitting (anchoring) surface. After the GSM device has been fitted the cable with a connector is
connected to the panel connector on the cover of the lubrication machine. After the connector is
connected the power feed indicator lamp lights up and the network indicator lamp begins to flash.
When the network indicator lamp lights up it means that the machine has successfully logged in the
mobile network. Each time the GSM module logs in the network (even after power failure) it sends an
SMS information message to the pre-set telephone numbers. If the information message is delivered,
the GSM module is correctly set and fully functional.
15.5 TECHNICAL PARAMETERS
GSM band Dualband - EGSM 900/ GSM 1800
Sending output 2W
Reception sensitivity -105dBm
Antenna 900/1800 MHz, antenna connector SMA
SIM card 3V plug-in
Input connector M12 – 5pin
Table.No. 3 Technical parameters of GSM
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 18 of 23 NO_PMP_ ENG 4-2013
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16 LUBRICATION PUMP ACCESSORIES
Pic.No. 14 Lubrication pump PMP accessories - page 1
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 19 of 23 NO_PMP_ ENG 4-2013
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Pic.No. 15 Lubrication pump PMP accessories - page 2
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 20 of 23 NO_PMP_ ENG 4-2013
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Pic.No. 16 Lubrication pump PMP accessories - page 3
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 21 of 23 NO_PMP_ ENG 4-2013
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Pic.No. 17 Lubrication pump PMP accessories - page 4
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 22 of 23 NO_PMP_ ENG 4-2013
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17 FAILURE REPORTS AND THEIR ELIMINATION
All malfunctions, failure statuses and information messages that may occur are described in a
systematic manner in Table 4. The table is divided into failures that are depicted on the automatic
system’s display and failures that are depicted in an incoming SMS message in the mobile phone.
Report Showing on display of
lubrication pump PMP
Showing via SMS on
mobile phone
Any impulse given from 1. reader E1
„Err cykle“ Any impulse given from 2. reader E2
Any impulse given from 3. reader E3
Low level of lubricant red „Low Level“
Connection control of a mobile phone with
PMP „Status“
Re-connection of PMP into an electric
power „RESTART“
Table.No.4 Table of failure reports
17.1 A LIST OF MOST FREQUENT FAILURES
The table below includes possible failures, their causes and possible ways how to perform repairs. It is
advisable to use this table when you try to eliminate a failure on your own as a user or as a means of
assistance when trying to identify the failure in contact with the manufacturer.
FAILURE PROBABLE CAUSE POSSIBILITIES HOW TO REPAIR
Lubrication machine is
connected to the electrical
mains but the lubrication
machine does not respond
(the display does not light up,
the motor does not start
revolving)
1. Wrong voltage on
connector clamps Check whether the feeding voltage on
the connector clamps is correct
2. Failure of the circuit
breaker or circuit protector
Switch on circuit breaker, protector
3. Faulty fuse
Change the fuse
No lubricant comes out of the
lubricating working unit
4. Very low level of lubricant
in the tank
Replenish the lubricant
5. Too much air in the
working unit
Loosen the inlet screws (G1/4) of the
working unit so that the lubricant could
come out. Put the lubricant machine to
operation and let it run at least for 30
seconds. Then again re-tighten the inlet
screws.
Lubrication pump PMP
Operating Instruction
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
page 23 of 23 NO_PMP_ ENG 4-2013
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FAILURE PROBABLE CAUSE POSSIBILITIES HOW TO REPAIR
The lubrication machine does
not generate pressure
6. Loose regulation piston on
the dosing unit
Re-tightening the screw will increase
the working pressure in the unit
7. Defective dosing unit
Change the working unit
When programming the
automatic system of the
lubrication machine it is not
possible to confirm (save) or
exit (not save) selected values.
8. Microswitch has been
pressed in a wrong way
The green (START/ENT) and red
(STOP/ESC) button has a microswitch
located on the keyboard in the middle.
Therefore it is necessary to press these
two button in the middle of the dividing
line.
The lubrication machine is in
the mode “number of cycles
and times of pause“. The
automatic system reports a
failure of the sensor “E1”
(“E2”, “E3”).
9. Clogged lubricating outlet
(outlets) from the monitored
place (places)
Check whether lubricant comes out
from all outlets of the monitored place
while the machine is running
10. Broken electrical cable from
the sensor
Check the electrical connection
between the sensor and the lubrication
machine
11.Short time has been set for
supervision of time the
lubrication is running
Make sure that the interval for
lubrication supervision is longer by
about a half than the real interval for
lubrication
Prolong the time in the program of the
automatic system
Non-standard depicting on the
display
12.Non-standard situation in the
automatic system
Press STOP /ESC button
Disconnect the machine from electrical
voltage, wait about 1 minute and then
again connect the machine to el.
voltage
The lubrication machine is in
the mode “number of cycles
and times of pause”. While the
lubrication machine runs the
cycles are not counted down
while minutes are (the
operation indicator lamp and
minute indicator lamp shine,
possibly also sec indicator
lamp)
13.Disconnected connector the
number of sensors
Check the connections of the connector
14. Identification of sensors is
connected in a wrong way
Check the wiring chart whether the
identification of sensors has been
connected correctly (figures 8 and 9)
A failure report has appeared
on the display of the
lubrication machine but the
SMS report has not been
delivered
15. Low credit on the phone
card
Check the credit status on the SIM card
16. Choking of data channels
on the receiver of the
telephone operator at the
place of use
The report will be delivered later
17. Low reception of GSM
signal
Order a GSM antenna with an incoming
cable and lead the antenna to a place
with a better reception of the signal
Table .No. 5 The list of errors and their correction
Lubrication pump PMP
Operating Instruction – Annex no. 1
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
NO_PMP_ ENG 4-2013
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Annex no. 1 – page 1/3
1 PMP PROGRAMMING (ABRIDGED VERSION)
The automatic system of the lubrication machine includes two programming modes:
1. LUBRICATION TIME – PAUSE TIME
2. NUMBER OF CYCLES – PAUSE TIME
The initial mode on the switching-on of the lubrication machine is Lubrication time – Pause
time. The transition to the second mode (Number of cycles – Pause time) is automatic. The lubrication
machine can recognize on its own whether the connector of contact-free sensors is connected and
switches over to the second mode.
DESCRIPTION OF THE CONTROL KEYBOARD
NOTICE
When no action is being performed in the programming mode after 10 seconds the automatic
system will automatically switch over to the operation mode without unsaved data.
It is possible to program the PMP lubrication machine only when it is not running (the
electromotor is not revolving). When the machine is running and you aim to start the programming of
the automatic system, press the STOP button. This will interrupt the running of lubrication and the
automatic system will switch over to the pause mode.
DESCRIPTION OF SIGNS
- the indicator lamp is not shining
- the indicator lamp is shining
- the indicator lamp is flashing
1. START/ENT button
2. STOP/ESC button
3. Choice button
4. LED operation indicator
5. LED pause indicator
6. LED cycle indicator
7. LED hour indicator
8. LED minute indicator
9. LED second indicator
10. LED MIN. level alarm indicator
11. Display
7
8
9
2
1
4
5
6
3 3 10
11
Operation status(standby status)
PROGRAMMING OF THE PMP LUBRICATION PUMP IN MODE: OPERATION TIME – PAUSE TIME
The cycles indicator lamp, the
display starts flashing
email: [email protected]
phone: +420 543 425 611
or
Connecting the
machine to the
electrical mains
Setting of the time interval for
pauze in hours(the pause indicator lamp and the minute
indicator lamp are flashing)
The pause indicator lamp and the seconds
indicator lamp light up, the display starts
flashing
The required value is set on the
flashing display
Save the set value
Confirmati
on of the
selection
Does not save the set value
The display
lights up
Setting of the time interval for
pauze in minutes(the pause indicator lamp and the minute
indicator lamp are flashing)
Setting of the time interval for
pauze in seconds(the pause indicator lamp and the second
indicator lamp are flashing)
Programming status
En
try
into
pro
gra
mm
ing
Exit fro
m
pro
gra
mm
ing
Mode 2 Mode 3 Mode 4 Mode 5
SYMBOLS:
Operating indicator lamp
Setting of the time interval for
operation in secounds(the operation indicator lamp and the secounds
idicator lamp are flashing)
Setting of the time interval for
lubricating operation
(the operational indicator lamp and the minutes indicator
lamp are flashing)
Mode 1
Annex no. 1 - page 2/3
Confirmati
on of the
selection
Confirmati
on of the
selection
Confirmati
on of the
selection
Confirmati
on of the
selection
The pauze indicator lamp and the minutes
indicator lamp light up, the display starts
flashing
The required value is set on the
flashing display
Save the set value
Does not save
the set value
Save the set value
Does not save the set value
The required value is set on the
flashing display
The pauze indicator lamp and the hours
indicator lamp light up, the display starts
flashing
The operating indicator lamp and the minutes
indicator lamp light up, the display starts
flashing
Save the set value
Does not save the set value
The required value is set on the
flashing display
Save
the set valueDoes not save the set value
The required value is set on the
flashing display
Pauze indicator lamp
Cycle indicator lamp
Low level indicator lamp
Operation status(standby status)
PROGRAMMING OF THE PMP LUBRICATION PUMP IN MODE: NUMBER OF CYCLES – PAUSE TIME
The cycles indicator lamp, the
display starts flashing
email: [email protected]
phone: +420 543 425 611
or
Connecting the
machine to the
electrical mains
Setting of the time interval for
pause in hours(the pause idicator lamp and the minutes
indicator lamp are flashing)
The pause indicator lamp and the seconds
indicator lamp light up, the display starts
flashing
The required value is set on the
flashing display
Save the set value
Confirmati
on of the
selection
Does not save the set value
The display
lights up
Setting of the time interval for
pause in minutes(the pause indicator lamp and the minute
indicator lamp are flashing)
Setting of the time interval for
pause in seconds(the pause indicator lamp and the second
indicator lamp are flashing)
Programming status
En
try in
to
pro
gra
mm
ing
Exit fro
m
pro
gra
mm
ing
Mode 2 Mode 3 Mode 4 Mode 5
SYMBOLS:
Operating indicator lamp
Setting of the number of
lubrication cycles(the cycle indicator lamp is flashing)
Setting of the time interval for
lubricating operation
in minutes during which the set number of cycles must
take place (the operational indicator lamp and the minute
indicator lamp are flashing)
Mode 1
Annex no. 1 - page 3/3
Confirmati
on of the
selection
Confirmati
on of the
selection
Confirmati
on of the
selection
Confirmati
on of the
selection
The pause indicator lamp and the minutes
indicator lamp light up, the display starts
flashing
The required value is set on the
flashing display
Save the set value
Does not save
the set value
Save the set value
Does not save the set value
The required value is set on the
flashing display
The pause indicator lamp and the hours
indicator lamp light up, the display starts
flashing
The operating indicator lamp and the minutes
indicator lamp light up, the display starts
flashing
Save the set value
Does not save the set value
The required value is set on the
flashing display
Save
the set valueDoes not save the set value
The required value is set on the
flashing display
Pause indicator lamp
Cycle indicator lamp
Low level indicator lamp
Lubrication pump PMP
Operating Instruction – Annex no. 2
TriboTec spol. s r.o.
Košuličova 4 www.tribotec.cz, [email protected]
619 00 Brno tel: +420 543 425 611
Czech Republic
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Annex no. 2 – page 1/2
PROGRAMMING OF THE GSM MODEM OF THE PMP LUBRICATION MACHINE
Before you start programming the GSM module of the PMP lubrication machine you have to
carry out the following procedure:
1. Before the GSM module is attached to the lubrication machine it is necessary to insert the
SIM card into the black box. The cover of the box is secured by four screws. After the
screws are removed the SIM card is inserted in the holder. Make sure the position of the
SIM card in the holder is correct. The GSM module is not blocked and therefore it is
possible to use a SIM card from any operator. The PIN code on the used SIM card must
not be active.
2. Copy a configuration file PMP_config.exe from the installation CD (or from the website of
Tribotec) into the newly created folder in the computer or laptop.
3. Connect the lubrication machine with the computer or laptop via an RS 232 connector.
The programming cable (figure 1) is connected to the lubrication machine via the
connector of the GSM module (figure 2). First you have to unscrew the connecting cable
of the GSM module and then screw on the connector of the programming cable. The
second end is connected to the RS 232 port.
Figure 1 Programming cable PMP – code:8550538 Figure 2 The place at which the
programming cable is connected
The configuration file has been created in such a way that it is only made of a single file. It is
not necessary to install anything. No further configurations or libraries are necessary. Switching on is
all that it takes.
The program has been designed for the Windows platform.
A detailed description of programming is given in Annex no. 2 – sheet no. 2.
After all parameters have been set disconnect the programming cable from the computer and the lubrication machine.
Insert again the connecting cable of the GSM module.
If you performed all steps correctly you should receive an information SMS message in about a minute on the preset
mobile number that will contain a report of the set data in the configuration program. If this does not happen you can try to
phone the lubrication machine from the given mobile phone. The lubrication machine should terminate your incoming phone call
(hang up) and in a minute or less you should receive the required information SMS message.
PROGRAMMING OF THE PMP LUBRICATION PUMP IN MODE: PROGRAMMING IN GSM MODULE email: [email protected]
phone: +420 543 425 611
Annex no. 2. - page 2/2
Select the port that you have
connected the PMP automatic system
to (it is usually port COM 1)
Step no. 2.
Start up the configuration program
PMP_config.exe. A configuration
window will open up.
Activate the corresponding port for this
appli atio the Ope port utto . The
status Connected to: COMx (x – port
number) will be written in the textual field.
Step no. 3.
Carry out the activation of the PMP control
timer into the configuration mode – this is
achieved by switching off the PMP for more
than 5 seconds.
The keep the “TOP/E“C utto pressed o the PMP and switch on the pump.
In 5 seconds a massage will appear in the
textual field that will confirm the connection
a d tra sfer to the o figuratio ode Config is ON . Transferring to the
configuration mode will also switch off
communication over the GSM modem, if it
was active.
Step no. 4. Usi g the Read config from PMP utto will upload the current configuration and present
it in the textual field.
This uploading is used to check the setting
and can be used at any time during the
process of configuration.
Step no. 5.
You can enter a telephone number in the
telephone number field – the PMP control
timer will communicate via this number.
Set to PMP utto will arr out a e tr into the PMP control timer. A confirmation
that the entry has been made correctly will be
writte i to the te tual field set Phone
Number -> +420543425611
Step no. 6.
Into the field for the PMP name you can enter
the name or number of the PMP unit to
provide for its identification. You can enter 8
symbols in total. Set to PMP utto will carry out an entry into the PMP control timer.
A confirmation that the entry has been made
orre tl will e writte i to the te tual field set Name -> TriboPMP
Step no. 7.
If you want to activate the communication
with the GSM modem you will achieve this by
pressi g Turn ON GSM utto . A
confirmation will be written in the textual
field: GSM modem -> ON .
This will also terminate the configuration
mode of the PMP control timer. After this the
PMP control timer starts communicating with
the GSM modem, this is shown in the textual
field that depicts phone calls of the GSM
modem.
Step no. 8.
Free the port for other applications by
pressi g the Close Port utto . This will be
displayed: Disconnected from:COMx (x –
the port’s u er)
Step no. 9.
Step no. 1.
Close the program by red X
Step no 10.