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Groeneveld EG1703P03 General Manual Download Page 41

Automatic Greasing System 

Twin-3

 

  

Maintenance

41

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EG1703P03

4.6.5

Malfunction finding procedures

A number of procedures to determine the correct cause of a certain malfunction are described
below.

Procedure to check pressure switch (valve) and its cable

1.

Disconnect the 2-pole connector from the pressure switch.

2.

Measure the resistance between the two contacts using a digital multimeter. When the sys-
tem is pressureless , the resistance should be 22K ohm. If required, remove the switch to make 
sure that no pressure below the pressure switch is present. Remove only the upper part, the 
diverter valve can be left in place.

3.

If possible, mount a pressure gauge that is suitable for a grease pressure up to 250 bar 
between the diverter valve and the pressure switch and bleed this connection before use.

4.

Switch ignition ON.

5.

Start a cycle test by pushing the test push-button at the pump.

6.

Check the switching moment of the pressure switch using the digital multi-meter. When the 
adjusted pressure (see the side of the pressure switch) is reached the contact should be closed, 
the resistance should ± 0 ohm.

7.

Switch ignition OFF for ending the cycle test.

If the pressure switch functions properly, the cable should be checked for internal damage.

8.

Connect both contacts of the connector of the pressure switch with a separate wire.

9.

Disconnect the pump connector.

10. Measure the resistance between pin 7 and 8 of the pump connector. The measured resistance 

should be ± 0 ohm.

11. Remove the wire between the contacts of the connector of the pressure switch. The digital 

multimeter should read an 

open load

.

ATTENTION
If a pressure switch without a resistor is being used in the greasing system you should measure an
open load.

Summary of Contents for EG1703P03

Page 1: ...General Manual Automatic Greasing System Twin 3 EG1703P03 Your efficiency is our Challenge Twin ASC Form 80 1052 Rev 9 2013 ...

Page 2: ...pplies to the standard version of the product Groeneveld cannot accept liability for any damage arising from the use of specifications other than that supplied You are requested to contact Groeneveld technical service for information concerning adjustment maintenance work or repairs that is not described in this manual Whilst this manual has been prepared with the greatest possible care Groeneveld...

Page 3: ...2 5 1 Principle of operation 19 2 6 Signal lamp 21 2 7 Duty mode push button 21 2 8 Twin 3 display 22 2 8 1 Decimal dot of the 3 digit display 23 3 System test 24 3 1 Introduction 24 3 2 Single greasing cycle test 25 3 3 Multiple greasing cycle test 26 3 4 Fast automatic cycle session 27 3 5 Resetting the system 27 4 Maintenance 28 4 1 General 28 4 2 Periodic checks 28 4 3 Bleeding the pump 28 4 4...

Page 4: ...Table of Contents 4 EG1703P03 Automatic Greasing System Twin 3 Date of issue January 2011 ...

Page 5: ... data on several components of the Twin automatic greasing system In this manual the following icons are used to inform or warn the user Use of symbols ATTENTION Draws the user s attention to important additional information meant to avoid problems WARNING Warns the user for physical injuries or serious damage to the equipment caused by improper ac tions Symbol Explanation BK Black BN Brown BU Blu...

Page 6: ... machine during oil replacement for instance Careful selection of construction materials makes the greasing system itself nearly maintenance free 1 2 The Twin automatic greasing system Groeneveld has developed a double line automatic greasing system especially for the use of NLGI class 2 grease The Twin system ensures that all the disadvantages of the systems currently available for class 2 grease...

Page 7: ...prises the following parts see Figure 1 1 1 An electric grease pump plunger pump with integrated grease reservoir and a digital control unit with data storage facility 2 Primary grease line A 3 Primary grease line B 4 Distribution block 5 Metering unit 6 Pressure switch 7 Secundary grease line Figure 1 1 System overview TWIN 1 3 5 6 2 4 7 ...

Page 8: ...n the circumstances The different greasing cycles and phases are discussed below Figure 2 1 Overview of the various phases of the greasing cycle 2 2 1 Greasing cycle A Pumping phase The greasing cycle begins with a pumping phase In this phase the grease is pumped from the reservoir through primary grease line A to the distribution blocks The pumping phase ends when the pressure at the pressure swi...

Page 9: ...ration of the pumping phase When the greasing system needs more time to build up the required grease pressure because of low temperature or grease with a high viscosity the system will also need more time to decrease that same pressure Pause phase The pause phase is the period between the pressure decrease phase and the beginning of the next pumping phase in line B The length of the pause phase is...

Page 10: ... channels to the primary lines A relief valve 14 and a 5 2 way valve 6 are located in the compression channel The relief valve is a protection that leads the grease back to the reservoir when the grease pressure exceeds 250 bar The 5 2 way valve determines the primary grease line A or B through which greasing takes place It has an important task in fulfilling the four phases of the greasing cycle ...

Page 11: ...he wiring diagram shown see Figure 2 3 The positive pole of the supply voltage 15 is connected to pin 1 As soon as the ignition is switched ON the program cycle is started at the point where it was interrupted during the preceding cycle If the preceding cycle was interrupted during the pumping phase by switching OFF ignition this pumping phase will be continued the moment ignition is switched ON a...

Page 12: ... can be started when power to pin 3 is switched ON power to pin 3 is switched OFF ground to pin 3 is switched ON ground to pin 3 is switched OFF Please refer to the Twin 3 Uni or PC GINA manual for the necessary parameter settings in order to activate one of the above mentioned possibilities Figure 2 4 Wiring diagram with command switch and Twin 3 display TWIN Automat c G ea ing System SW TCH PUMP...

Page 13: ...ll only be useful in combination with such a pump see internal wiring of pump connector pin 4 and 5 PUMP L 12V 20A 24V 10A 22K 120 Ohm 5 1W 12V 3A 24V 3A T BK RD GN BU GY PK OR P I I CAN CPU 1 15 3 7 PS 8 6 K 5 PS 4 L H 2 GND VAL1 PUMP POWER J5 J8 3 4 VAL2 LOW TEST 1 2 3 4 5 6 7 8 9 10 11 1 Electric motor of pump 2 5 2 way valve 3 Minimum level switch 4 Test push button 5 Control unit 6 Pump housi...

Page 14: ... of the greasing cycle and the influence of the position of the 5 2 way valve on the greasing cycle see paragraph 2 2 2 3 3 Relief valve A relief valve is mounted in the grease line between the piston pump and the 5 2 way valve see Figure 2 2 14 When the grease pressure exceeds 250 bar during the pumping phase the relief valve will redirect the grease to the reservoir The maximum grease pressure w...

Page 15: ... of a draw spring The grease follower plate locks out air and condensation so preventing oxidation of the grease mingling of the grease with the water of condensation saponifying of the grease The grease level in the reservoir can always be determined at a glance because the grease follower plate scrapes the walls of the reservoir Also the follower plate prevents funnel forming in the grease so th...

Page 16: ...ts and secondary grease lines Unused ports are sealed with a blind plug A pressure switch can also be mounted into one of the ports Because of their closed construction the metering units are exceptionally well suitable for use in dirty and dusty environment The metering units and distribution blocks are made of brass or stainless steel The various metering units are distinguished from each other ...

Page 17: ...phase the metering unit has not yet been filled with grease Figure 2 8 First phase While in operation system completely filled with grease phases 3 and 4 will take place alternately Phase 2 During pumping phase A grease is pressed into channel A While the grease pressure is built up piston 3 is pushed to the right passed channel 1 The grease fills chamber 2 through channel 1 and pushes piston 4 to...

Page 18: ...back to clear the path to the secondary grease line Figure 2 10 Third phase After a while the pressure drops in the primary grease line B during the pressure decrease phase of the greasing cycle This has no influence on the metering unit Phase 4 In this phase the same happens as in phase 2 However chamber Figure 2 10 7 is now filled with grease Piston 4 is pushed to the right while chamber 2 is fi...

Page 19: ...middle or at the beginning of the greasing system a switch with a higher switch pressure is applied Pressure switches are delivered with switch pressures of 100 125 150 or 175 bar 2 5 1 Principle of operation The principle of operation of the pressure switch is explained in three phases Phase 1 During this phase no pressure is on channel A and B There is also no pressure in chamber 1 Spring 10 pus...

Page 20: ...el 12 The grease pressure pushes piston 6 to the left Because of that the channel 8 is opened causing the grease to flow to chamber 1 through channel 7 and 9 As soon as the pressure in chamber 1 is higher than the pressure force of the spring 10 the piston 2 goes to the right The electrical contact 3 and 4 is closed by the contact plate 5 Figure 2 14 Third phase During the pressure decrease phase ...

Page 21: ... button influences the length of the pause phase It is also possible to retrieve the fault codes on the signal lamp by using the duty mode push button see paragraph 4 6 4 Figure 2 16 Mode push button with signal lamp Proceed as follows to change the active duty mode 1 Switch ignition ON 2 Depress the push button once heavy duty twice medium duty or three light duty times for 1 second 3 The lamp wi...

Page 22: ...es a malfunctioning Figure 2 17 Twin 3 display Proceed as follows to change the active duty mode 1 Switch ignition ON 2 Push the switch button for at least 5 seconds Accordingly the 3 digit display starts flashing 3 Push the switch button repeatedly until the desired duty mode shows 4 Leave the desired duty mode flashing for at least 6 seconds until the duty mode comes on This will confirm the des...

Page 23: ...d greasing output Medium duty Greasing mode with medium intervals Normal greasing output Heavy duty Greasing mode with short intervals Increased greasing output Pump performs a single cycle test LED flashes slow See paragraph 3 2 Pump performs multiple cycle test LED flashes fast See paragraph 3 3 Pump performs a number of fast automatic cycles See paragraph 3 4 When the pump is performing fast au...

Page 24: ...it will flash rapidly 0 2 sec on 0 2 sec off and code T2 will show at Twin 3 display Only the signal lamp will light continuously for 2 minutes in the end of each failed cycle test After the pump has been disabled due to a number failed cycles in succession the display will show the initial cause by means of an fault code see paragraph 4 6 4 This code can also be visualized by the signal lamp see ...

Page 25: ...h ignition ON b Push the switch button at least for 5 seconds Accordingly the 3 digit display starts flashing c Push the switch button repeatedly until code T1 shows d Leave the code T1 flashing until the code comes on The system will operate a single greasing cycle See also next alinea During the operation the green LED at Twin 3 display will flash slowly 2 sec on 2 sec off A code T1 and a runnin...

Page 26: ...T2 flashing until the code comes on The system will operate a multiple greasing cycle See also next alinea During the operation the green LED at Twin 3 display will flash quickly 0 2 sec on 0 2 sec off A code T2 and a running decimal dot will be indicating its pump pressure retaining and pressure decrease phase at Twin 3 display e The multiple greasing cycle can be finished by simply switching ign...

Page 27: ...e use of an Uni or PC GINA a Change the preset amount of fast automatic cycles to 0 in parameters b Select either Auto F1 Single test F3 or Multiple test F4 When during the session a number of cycles fail in succession the session ends and pump disables The Twin 3 display will show the red LED and the cause by error code see Malfunction reports of Twin 3 display on page 34 All data during such a s...

Page 28: ... filter is located behind the external filler coupling beneath the reservoir 10 Check the stored data in the control unit with the use of an Uni or PC GINA 4 3 Bleeding the pump When the system malfunctions repeatedly due to an empty grease reservoir it is possible that the pump needs to be bled Proceed as follows 1 Make sure that the grease reservoir is filled 2 Remove both primary lines from the...

Page 29: ...the pump for at least 6 seconds multiple cycle test Because the end plugs are removed no grease pressure is built up When the maximum pumping time has past the system switches automatically to the other primary line This is repeated until the ignition is switched OFF 5 Switch ignition OFF as soon as pure grease without air pockets comes from the primary lines 6 Re mount the end plugs into the dist...

Page 30: ...ew fillerpump or hose is used ensure no air is left in it Prime fillerpump and hose to avoid air pockets being pumped into Twin 3 pump reservoir 2 Remove the dust cap from the filler coupling 3 Carefully clean the filler coupling and coupling on the filler hose used 4 Fix the filler hose on the filler coupling 5 Fill the reservoir up to maximum level indicated on the reservoir 6 The bottom of foll...

Page 31: ...der the grease follower plate through the bleeding channel in the grease follower plate guide The bleeding channel is opened when refilling of the grease is done above the maximum level 4 6 Finding malfunctions 4 6 1 General The Twin greasing system is equipped as standard with an electronic control unit with a database All relevant data concerning the functioning of the greasing system are stored...

Page 32: ...l lamp broken c Replace signal lamp if necessary d Wiring interruption between power supply and the control unit or between control unit and signal lamp d Check and repair wires if necessary 2 Lamp flashes for 2 minutes 0 5 sec on 0 5 sec off at the beginning of each cycle Minimum level in the reservoir has been reached Resets itself by refilling the reservoir 3 Lamp continuously lit after the ign...

Page 33: ...a d Check and mount a new O ring if necessary Also see Procedure when an internal system leak is suspected on page 43 e 5 2 way valve broken preventing pressure build or release in primary line A or B Because of this no pressure can be built up or released e See Procedure to check pump and 5 2 way valve on page 42 f Internal leak of metering unit or pressure switch valve f Replace the metering uni...

Page 34: ...al timer a Check whether wire no 3 for stopping the interval timer is connected correctly see wiring diagram Figure 2 4 and that of the vehicle when available Repair when necessary b The green command wire no 3 is stopping the interval timer b Check with the use of an Uni or PC GINA whether the timer activation options are set correctly Change these parameter settings when necessary 3 Successive n...

Page 35: ...l closed at the outset of a cycle in primary line A Possibly caused by a Damaged PS wiring harness to where wires are joined a Check wiring and connectors Replace or repair when necessary b 5 2 way valve did not operate correctly b Check 5 2 way valve and operate manually with the use of an Uni or PC GINA Replace or repair when necessary c Pressure switch failed broken c Check and or replace press...

Page 36: ...r replace battery b Faulty wiring ground wire b Check wiring Replace or repair when necessary c Corroded pin contact in connec tor c Check connections at pump and in cabin Replace or repair when necessary 9 Faulty pressure switch circuit The pressure switch did not close during a greasing cycle in primary line A or B while control unit noticed a deviant resistance over the pressure switch circuit ...

Page 37: ...able for the extreme low working temperature e Increase the pump motor current limit parameter setting but only after checking whether the vehicle wiring and fuse can handle a higher setting 12 Successive valve 1 open loads Control unit detected a too low current draw to first coil of the 5 2 way valve in combination with initial system on pressure before cycle error caused by a Interrupted wiring...

Page 38: ...ir when necessary 16 Communication error with control unit a No communication between display control unit a Check the purple communication wire no 6 between display and pump pump connector pin no 6 Repair when necessary b No supply voltage at the pump b Check the fuse and red power wire no 1 to pump connector no 1 and the black ground wire no 2 to the pump connector no 2 Replace or repair when ne...

Page 39: ... run wiring b Check the interval clock command wiring and connection green wire no 3 pump connector pin no 3 c The interval clock does not run parameter c Check with the use of an Uni or PC GINA whether the timer activation options are set correctly 2 All grease points are over greased The set greasing interval for the application is too short Choose the low duty mode with the switch button and or...

Page 40: ...mp to shut off ATTENTION Fault codes can only be retrieved when the pump communication line pin wire no 6 is not connected to an Uni or PC GINA and need to be disconnected for at least 50 seconds before a code can be retrieved Pulse Fault code long short short short short 14 long long short 21 Fault code Meaning 11 No pressure line A 12 No pressure line B 13 Pressure before cycle in line A 14 Pres...

Page 41: ...the pressure switch and bleed this connection before use 4 Switch ignition ON 5 Start a cycle test by pushing the test push button at the pump 6 Check the switching moment of the pressure switch using the digital multi meter When the adjusted pressure see the side of the pressure switch is reached the contact should be closed the resistance should 0 ohm 7 Switch ignition OFF for ending the cycle t...

Page 42: ...umping element Temperature too low and or grease is too viscous Therefore it is not sucked in by the pumping piston Replace the grease in the reservoir and the primary grease lines by more suitable grease for the aimed temperature Pump is faulty Replace the pump 5 End the cycle test by switching the ignition OFF or by disconnecting the pump connector for a moment 6 Switch ignition ON 7 Start anoth...

Page 43: ...from block channel B directly after the first distribution block after the pump 5 Restart the pump in channel A When the grease leaks from outlet B of this first distribution block the leak must be found in this block When the grease leaks from the disconnected primary grease line the leak must be sought farther down the system Therefore repeat this procedure every time using the next distribution...

Page 44: ...dc Advised fusing 10A 24 Vdc 20A 12 Vdc Capacity grease reservoir 2 3 4 6 or 8 litres Nominal grease output 12 cm min Grease follower plate standard Minimum level switch standard Pump material hard anodised aluminium nylon reinforced Protection class IP67 The Twin automatic greasing system complies to the electromagnetic compatibility requirements of Automotive directive 72 245 EC as last amended ...

Page 45: ...cal data 45 Date of issue January 2011 EG1703P03 Figure 5 2 Dimensions Twin pump with a 6 or 8 litre reservoir 5 2 Signal lamp Max allowed power consumption 3W 250 270 162 49 100 L1 L2 L1 mm 326 415 Reservoir 6 Litres 8 Litres L2 mm 475 564 ...

Page 46: ... 104 EC Industrial equipment 2004 108 EC Environment Ambient operating temperature range 25 70 C Storage temperature range 25 70 C Casing humidity dust IP54 Electrical Supply operating voltage range 9 32 VDC Max operating current 220 mA Open drain outputs max current 250 mA Open drain max voltage 32 VDC Cable length max 5 meter TWIN Automatic Greasing System SWITCH 18 2 32 1 4 0 29 0 23 0 23 0 70 ...

Page 47: ......

Page 48: ...oeneveld Transport Efficiency B V Stephensonweg 12 4207 HB Gorinchem P O Box 777 4200 AT Gorinchem The Netherlands Ph 31 183 641 400 F 31 183 624 474 http www groeneveld group com www groeneveld group com ...

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