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Table of Contents

F212157R02

Automatic Greasing System

TriPlus Trailer

Date of

is

sue :

Sept

e

m

ber

2

012

Table of Contents

Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

The TriPlus automatic greasing system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

Description components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

Properties - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

Composition of the TriPlus trailer pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

The intigrated control and monitoring unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

The plunger pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Safety and control features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
2.5.1.

Maximum grease pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

Minimum grease-level in the reservoir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

Defective wiring and short-circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

The test pushbutton - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
2.6.1.

Performing a test cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

Retrieving fault messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

The signal light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

The distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.8.1.

Properties- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

Composition- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

Principle of operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Non-return valves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Failure of one of the doser segments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Closing outputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Combining outputs- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

The GINA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Connecting the GINA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Control pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Switching on the GINA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Main menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20

Parameters timer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

Diagnosis menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

Layout of the menu system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
3.8.1.

Used abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31

Main menu- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

Parameters menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

Diagnosis menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34

Designing a system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

Points of departure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

Method - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
4.3.1.

Determine the operating conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37

Produce a greasing plan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37

Determine the grease demand of the grease points - - - - - - - - - - - - - - - - - - - 37

Group the grease points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38

Determine the layout of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38

4.3.6.

Check the design - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

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Содержание TriPlus Trailer

Страница 1: ...General Manual Automatic Greasing System TriPlus Trailer F212157R02 Your efficiency is our Challenge...

Страница 2: ...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 technic...

Страница 3: ...13 2 8 The distribution blocks 15 2 8 1 Properties 15 2 8 2 Composition 15 2 8 3 Principle of operation 16 2 8 4 Non return valves 17 2 8 5 Failure of one of the doser segments 17 2 8 6 Closing outpu...

Страница 4: ...couplings 44 5 6 1 Grease line types 44 5 6 2 Mounting the primary grease lines 44 5 7 Secondary grease lines and couplings 46 5 7 1 Grease line types 46 5 7 2 Mounting the secondary lines 47 5 8 Elec...

Страница 5: ...m s operation and possibilities Furthermore in this manual you will find the technical data on several components of the TriPlus automatic greasing system In this manual the following icons are used t...

Страница 6: ...stems are designed with the utmost care and tested rigorously This guarantees an extended operational life and error free operation even under the most extreme operating conditions Proper installation...

Страница 7: ...those segments are combined in distribution blocks A Groeneveld TriPlus automatic greasing system comprises the following parts see Figure 1 1 1 An electric grease pump plunger pump with integrated gr...

Страница 8: ...m is not always available while the vehicle trailers or machine is in operation The trailer pump unit features an integrated control unit The most significant properties of the TriPlus trailer pump un...

Страница 9: ...rol and monitoring unit with permanent memory 5 Relief valve with return line to the grease reservoir and electric contact for monitoring purposes by the control unit 6 Grease output port 1 7 Impulse...

Страница 10: ...h a GINA Groeneveld tester for INstallation and Analysis see Figure 2 2 Figure 2 2 Connecting the GINA to the trailer pump 2 4 The plunger pump The electric motor drives the plunger pump through a red...

Страница 11: ...when one of the grease lines to the grease points has become blocked or when the viscosity of the grease has become too high at low temperature 2 5 2 Minimum grease level in the reservoir A minimum le...

Страница 12: ...cated by the signal light and will not be stored in the memory of the control unit 2 6 2 Retrieving fault messages In the memory of the control unit information is stored about the operation of the gr...

Страница 13: ...4 The signal light The signal light produces the following signals Signal Moment Significance 1 x 3 seconds on 5 seconds after switching on contact The supply voltage for the control unit is available...

Страница 14: ...e long long short short fault code 22 two second pause Each fault message has been assigned a two digit fault code Fault code Meaning 10 No error on this moment 11 Distribution block monitoring switch...

Страница 15: ...ed in series in which case an output of a block is used to feed the next block in line through a primary grease line 2 8 2 Composition A progressive distribution block comprises the following componen...

Страница 16: ...now flows via piston 2 to the left hand side of piston 3 Piston 3 is pushed to the right and supplies lubricant to output port 3 4 After piston 3 has been pushed to the right the lubricant is pressed...

Страница 17: ...s An output may only be closed off after removal of the little plug that seperates the two outputs of a doser segment Removing the plug allows the grease meant for the close off to exit through the ou...

Страница 18: ...roach The read outs and setting have been grouped in three menus main menu para meters timer and diagnosis menu You can access each of these menus by pressing MAIN PARAMETERS or DIAGNOSIS on the keypa...

Страница 19: ...pressing respectively MAIN PARAMETERS or DIAGNOSIS This message appears when the GINA is unable to communicate with the control unit This can be cause by bad connection wire in cable broken or bad con...

Страница 20: ...control unit ATTENTION This date and time will be updated when you switched off the GINA Press F3 u ch The screen shows the identification number of the person who most recently changed any settings o...

Страница 21: ...program trailer version device 8 You cannot change this setting Press NEXT The screen shows the version number of the software in this GINA Press NEXT The screen shows the version number of the displa...

Страница 22: ...and time You cannot change this setting Press F2 mnth The screen shows the month of the current date and time You cannot change this setting Press F3 year The screen shows the year of the current dat...

Страница 23: ...olution of its drive shaft determined by the stroke length and diameter of the plunger With this para meter the program will be able to calculate the number of revolutions needed to achieve a certain...

Страница 24: ...in milliseconds the control unit tolerates an overcurrent or short circuit in the electric motor of the pump before it disconnect the electric motor The default is 50 ms and value should not be change...

Страница 25: ...e pressure was exceeded during a pump phase Press F3 lowl The screen shows the number of greasing cycles in which the grease level switch in the reservoir reported a low grease level Press F4 rto The...

Страница 26: ...n shows how many times open load in the signal light circuit has been occured Press NEXT The screen shows how many times over current in the signal light circuit has been occured Press NEXT The screen...

Страница 27: ...f the greasing system are operated by hand by means of the GINA 2 test the system is performing a test cycle amount dependent on parameter setting You can change the current operating mode by pressing...

Страница 28: ...AGNOSIS Press F3 var The screen shows the remaining part expressed in brake commands of the current greasing interval Press F2 rrev The screen shows the remaining part of the number of revolutions of...

Страница 29: ...ss F1 pdif The screen shows the part number of the control unit PCB Press F2 srno The screen shows the serial number of the control unit PCB Press F3 tive The screen shows a version number which denot...

Страница 30: ...e ignored by the program Press F3 tpt The screen shows the total pumping time of the pump unit Press F4 skrv The screen shows the total number of revolutions of the drive shaft of the pump that were s...

Страница 31: ...last change day day del delivery output 1 end1 end switch in the system connected to output port 1 err errors hist history hrs hours I O inputs outputs info information GINA lol lamp open load lwl lo...

Страница 32: ...shaft rerr relief valve errors rrev remaining number of revolutions for the current pump phase rto revolution time out skrv total number of revolutions of the drive shaft that were skipped spr spare...

Страница 33: ...Trailer The GINA 33 Date of issue September 2012 F212157R02 3 8 2 Main menu 3 8 3 Parameters menu MAIN u ac d ac u ch d ch p s p ui acces info hrs min day mnth year time contr NEXT PARAMETERS mre poct...

Страница 34: ...4 Diagnosis menu DIAGNOSIS err prno srno tive tcy tbrk tpt skrv I O hist var tinfo NEXT mode pdiff rbrk rrev rerr rcem poc rdgr lowl rto pump spr lamp spr end1 eres pol lol pol lowl test rvlv loc end...

Страница 35: ...stem is expected to function 4 2 Points of departure Pump Maximum working pressure 275 bar Number of grease output ports 1 Distribution blocks Maximum number of distribution blocks in series 2 Availab...

Страница 36: ...cc Table 2 Internal resistance in a distribution block bar Grease class T C 3 doser segments 8 doser segments 12 doser segments NLGI 2 20 14 bar 16 bar 22 bar 10 28 bar 24 bar 26 bar 0 34 bar 44 bar 5...

Страница 37: ...wing and number them 4 3 3 Determine the grease demand of the grease points Note the grease demand per particular period of each grease point in a particular period on the greasing plan The grease dem...

Страница 38: ...number of doser segments that can be combined in a single distribution block Calculate the grease demand of the whole distribution block per whole cycle of the distribution block the sum of all rated...

Страница 39: ...ase point is connected to this grease line Determine the resistance Ps induced by that type of grease point see 5 2 Points of departure 4 Calculate the largest total loss of pressure Pt for each outpu...

Страница 40: ...prevent bodily harm and damage before you start working on the vehicle 3 Ensure the vehicle is immobilised before you start work Remove the ignition key and store it in a safe place Block parts that...

Страница 41: ...and clean the areas on the vehicle or machine where the distribution blocks and pump unit are to be mounted before you start installing them Even small contaminations can cause the greasing system to...

Страница 42: ...cle specific greasing plan determine in consultation with the client the most suitable location of the pump unit on the vehicle Take account of The pump unit must be easily accessible for filling its...

Страница 43: ...assembled 2 Check whether all required components are at hand and whether the right couplings for the right kinds of secondary grease line are available 3 Begin by placing the start segment to which t...

Страница 44: ...grease lines and couplings 5 6 1 Grease line types The primary grease lines are those between the pump unit and the distribution blocks and between the distribution blocks themselves The primary greas...

Страница 45: ...tely c Slide use some oil if necessary the pillar or the required coupling pin into the end of the grease line until the pillar is completely in the grease line d Pull the sleeve back slightly until i...

Страница 46: ...olyamide lines with outside diameters of 3 16 or 6 mm standard Stainless steel lines with the outside diameters of 3 16 or 6 mm standard Kunifer copper nickel lines with outside diameters of 3 16 or 6...

Страница 47: ...be used at grease point will have been noted on that plan First remove the existing grease nipple at the grease point and replace it by the required coupling s If the grease point to be connected is a...

Страница 48: ...to the junction box 5 8 2 Fuse ratings 5 8 3 Pin layout of the connector on the pump unit ATTENTION To prevent damage to the electrical system of the vehicle or machine the correct fuses must be insta...

Страница 49: ...ember 2012 F212157R02 5 8 4 Wiring diagram 1 Pump unit 2 Revolution sensor 3 Relief valve 4 Test pushbutton 5 Minimum grease level switch 6 Control unit 7 Pump motor 8 End distribution switch 9 Signal...

Страница 50: ...e aereted properly when a closed collar of fresh grease is present at all grease points 5 10 Commissioning of the greasing system During commissioning the system parameters greasing interval grease su...

Страница 51: ...unit either by using the test pushbutton on the pump unit or by connecting a GINA to the control unit 4 The primary and secondary grease lines for damage and leakage 5 The grease points collar of fres...

Страница 52: ...iller coupling 2 Clean the filler coupling and the coupling on the hose thoroughly 3 Lock the hose onto the filler coupling or position the grease gun onto the filler coupling 4 Fill the reservoir up...

Страница 53: ...lfunctioning Retrieve the fault codes with the test pushbutton or the GINA and repair the system All grease points connected to one of the grease output ports of the pump unit are too dry but no malfu...

Страница 54: ...ed during a pump phase 1 System contains grease that is not suitable for the current operating conditions Solution Replace the grease in the pump and flush the sys tem 2 Distribution block grease line...

Страница 55: ...sions of the TriPlus pump unit with a 3 litre reservoir Maximum operating pressure 250bar Operating temperature 20 85 C Supply voltage either 12 or 24 Vdc Rating pump motor nominal at 20 C 36 W Rest c...

Страница 56: ...um number of doser segments 3 excluding start and end segments Maximum number of doser segments 12 excl start and end segments Material galvanised steel Material O rings NBR Grease inlet port thread M...

Страница 57: ......

Страница 58: ...eneveld 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...

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