General Manual - Groeneveld Lubrication Solutions · 2016. 12. 15. · General information...

General Manual

Automatic Greasing SystemEcoPlus

F214317R01

YOUR EFFICIENCY IS OUR CHALLENGE

All rights reserved. No part of this manual may be copied and/or published by means of printing, photocopying, microfilm or by any other means without prior written permission from Groeneveld. This applies also to the drawings and diagrams appended.

Groeneveld reserves the right to change parts at any time, without prior or direct notice to the customer. The contents of this manual may also be changed without prior notice.

This manual applies 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 cannot accept responsibility for any errors of the concequences of such errors.

General information

Type of manual General ManualSystem EcoPlus Automatic Greasing SystemDocument number F214317R01Release date April 2016Revision 01

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TABLE OF CONTENTS1. PREFACE ................................................................................52. GENERAL INFORMATION ...................................................7

2.1 Introduction .................................................................................................................... .. 82.2 The EcoPlus automatic greasing system .............................................................. .. 9

3. COMPONENT DESCRIPTION ........................................ 113.1 Composition of the EcoPlus Pump unit ................................................................ 123.2 The control unit ............................................................................................................. 133.3 Behaviour during power off / on ............................................................................. 133.4 The piston pump ........................................................................................................... 133.5 Safety and control features ....................................................................................... 14

3.5.1 Relief valve .............................................................................................................143.5.2 Low level indicator (optional) .........................................................................143.5.3 Over pressure indicator (optional) ................................................................143.5.4 Manometer ...........................................................................................................143.5.5 Revolutions of pump drive shaft ...................................................................153.5.6 Defective wiring and short-circuits ..............................................................153.5.7 Block switch (optional) ......................................................................................153.5.8 Signal light (optional) ........................................................................................16

3.6 The Divider blocks ........................................................................................................ 163.6.1 Properties ...............................................................................................................163.6.2 Composition .........................................................................................................163.6.3 Principle of operation ........................................................................................173.6.4 Non-return valves ...............................................................................................183.6.5 Failure of one of the divider segments ........................................................183.6.6 Closing outputs ...................................................................................................183.6.7 Combining outputs ............................................................................................18

4. DESIGNING A SYSTEM ........................................................194.1 Introduction .................................................................................................................... 204.2 Points of departure ...................................................................................................... 204.3 Method ............................................................................................................................. 22

4.3.1 Determine the operating conditions ..........................................................224.3.2 Produce a greasing plan ...................................................................................224.3.3 Determine the grease demand of the grease points .............................224.3.4 Group the grease points ...................................................................................234.3.5 Determine the layout of the system. ............................................................23

EcoPlus

F214317R014

Automatic Greasing SystemR

elease date: August 2016

5. INSTALLATION .....................................................................255.1 Overview .......................................................................................................................... 265.2 Safety precautions ........................................................................................................ 265.3 General installation directives .................................................................................. 265.4 Mounting the pump unit ........................................................................................... 275.5 Divider blocks ................................................................................................................. 27

5.5.1 General ....................................................................................................................275.5.2 Assembly ................................................................................................................275.5.3 Mounting ...............................................................................................................28

5.6 Primary grease lines .................................................................................................... 285.6.1 Line types ..............................................................................................................295.6.2 Crimp diameter ....................................................................................................295.6.3 High pressure hose assembly .........................................................................29

5.7 Secondary grease lines and couplings ................................................................. 305.7.1 Grease line types .................................................................................................305.7.2 Installing the secondary lines .........................................................................30

5.8 Electrical wiring ............................................................................................................. 315.8.1 Fuse ratings ...........................................................................................................315.8.2 Pin layout of the connector on the pump unit .........................................32

5.9 Bleeding the system .................................................................................................... 365.10 Commissioning of the greasing system ............................................................... 365.11 Performing a test cycle ............................................................................................... 37

6. MAINTENANCE .....................................................................396.1 General ............................................................................................................................. 406.2 Regularly checks of the greasing system ............................................................. 406.3 Replacing the grease cartridge. ............................................................................... 41

6.3.1 Wiring diagram ....................................................................................................42

7. USER INTERFACE ................................................................437.1 Introduction .................................................................................................................... 44

7.1.1 Function keys ........................................................................................................447.1.2 Commands ............................................................................................................447.1.3 Access levels .........................................................................................................457.1.4 Accessing Supervisor mode ............................................................................45

7.2 Main menu ...................................................................................................................... 457.3 Information menu ........................................................................................................ 467.4 Parameter menu ........................................................................................................... 47

7.4.1 Trailer sub-menu .................................................................................................497.4.2 Cmd input sub-menu ........................................................................................507.4.3 Example of changing a parameter................................................................51

7.5 Diagnostics menu ......................................................................................................... 527.5.1 Errors ........................................................................................................................527.5.2 Inputs sub-menu .................................................................................................54

7.6 Trouble shooting ........................................................................................................... 557.6.1 Recognizing malfunctions ...............................................................................557.6.2 General malfunction reports ..........................................................................557.6.3 Error codes by signal light................................................................................577.6.4 Error codes by user interface ..........................................................................57

8. TECHNICAL DATA .................................................................608.1 Technical data pump unit .......................................................................................... 618.2 Distribution blocks ....................................................................................................... 62

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1. PREFACE

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F214317R016 Preface



This general manual gives a description of the EcoPlus Automatic Greasing System. It aims at giving insight in the system’s operation and possibilities. Furthermore, in this manual you will find the technical data of several components of the EcoPlus Automatic Greasing System.

In this manual the following icons are used to inform or warn the user:

ATTENTION

Draws the user’s attention to important information meant to avoid problems.

WARNING

Warns the user for physical injuries or serious damage to the equipment caused by improper actions.

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2. GENERAL INFORMATION

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F214317R018 General information



2.1 Introduction

With a Groeneveld automatic greasing system, all the connected grease points of the vehicle or machine are automatically lubricated with exactly the right amount of grease at just the right moment. In addition, optimum grease distribution is attained over the whole surface to be lubricated, All actions are automatically performed by the system. The operator needs only to ensure the periodic change of the grease cartridge.

Groeneveld’s automatic greasing system has been thoroughly tested to guarantee a long and trouble-free service life, even under severe operating conditions.

Besides correct installation and the use of the prescribed type of grease, a periodic check of the operation is a condition for the continued good functioning of the system. This peri-odic check is easy to carry out and can be done together with the usual maintenance of the machine. Partly through a careful choice of materials, the automatic greasing system proper is practically maintenance-free.

ATTENTION

The use of an automatic greasing system eliminates a large proportion of the time-consuming work of manual lubricating. Do not forget, however, that there are still lubrication points that have to be lubricated by hand.

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2.2 The EcoPlus automatic greasing system

The EcoPlus is designed for use on vehicles and machines with there own power supply for powering the greasing system when in operation. A version of the EcoPlus is available for use on trailers where power is supplied by the brake lights.The amount of grease that will be supplied to each connected grease point is governed by ratios that result from a choice of divider segment types and the manner in which these seg-ments are combined in the assembled divider blocks.The pump unit can be extended with a second grease outlet. In this way the greasing system can be separated in two systems parts on more complex vehicles or machines

A Groeneveld EcoPlus Automatic greasing system comprises of the following parts :

• An electric grease pump with cartridge and integrated digital control unit.• One or more divider blocks (composed of multiple divider segments).• Primary grease lines between the pump and the divider blocks and interconnecting the

divider blocks themselves.• Secondary grease lines between the divider blocks and the individual grease points.

3 1 1 4 1

1 3 1 2 1

1 1 3 2 1 1

1. EcoPlus pump2. Primary grease lines3. Distribution blocks4.Seconday grease lines

421 3

An EcoPlus pump is standard delivered with :• One grease outlet No. 5 (0.25cc)• Display with user-interface (with control unit and data storage)• Manometer for pressure indication• Supply voltage 12 Vdc or 24 Vdc

Options available.• Pistons available in sizes;

• No. 3 = 0.15cc, No. 4 = 0.20cc or No.5 = 0.25cc• Block switch for monitoring grease flow on divider blocks.• Visual overpressure indicator• Low level switch• Signal lamp

EcoPlus

F214317R0110 General information



Notes

11F214317R01 Component description

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3. COMPONENT DESCRIPTION

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F214317R0112 Component description



3.1 Composition of the EcoPlus Pump unit

1

2

5

6

13

4

3

9

1

7

11

14

10

12

8

1. Cartridge cover kit2. Low level magnet ring3. Grease cartridge NLGI-24. Wiring harness.5. Motor cover.6. PCA unit 12/24 Vdc7. Motor 12 or 24 Vdc8. Pump body9. Pump Flange

10. Pump element (no.3,4 or 5 11. Relief valve with manometer12. Low level indicator13. Plug M12x1.514. Plug M20x1.5


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3.2 The control unit

The control and monitoring unit initiates and controls the greasing cycles of the greasing sys-tem. All required system and program parameters (e.g. interval time, grease delivery) can be set. The control unit monitors the performance of various components of the greasing system and processes, stores and reports the malfunctions it detects.

The control unit can be programmed or read out using the user interface on the display

Power supply

Ground

Motor -

Motor +

Input A contact 1

Input A contact 2

Input B contact 1

Input B contact 2

Lamp output

Low level sensor contact 1

Low level sensor contact 2Motor rotation +

Motor rotation -

Motor rotation signal

Display information

Display light ground

Keypad

Display light power

3.3 Behaviour during power off / on

When power to the system is switched off (power down), the software saves several variables in the control unit memory bank. These are retrieved at power on, so the software can resume operation at the point when the power was switched off. This means that when, for example, the system is switched off during a pump cycle, the remaining pump revolutions needed to finish the pump cycle are stored in the memory bank. When the system is powered again, the previously aborted pump cycle is resumed and the remaining pump revolutions finished.

3.4 The piston pump

The electric motor drives the plunger pump through a reduction gear. The motor powers a drive shaft with eccentric cam, a cylinder with piston and a non-return valve. The eccentric cam moves the piston back and forth, once every revolution of the cam shaft. During the return stroke of the piston, grease is sucked from the cartridge into the cylinder During the forward stroke of the piston, the grease is pressed, via the non-return valve, to-wards the outlet(s) of the pump unit. The amount of grease supplied during each stroke (revolutions of the cam shaft) depends on the (fixed) diameter of the cylinder and the stroke length of the piston.

EcoPlus




3.5 Safety and control features

3.5.1 Relief valve

A relief valve is installed directly after the pump outlet. This relief valve leads the grease back to the reservoir if the maximum grease pressure (270 bar) is exceeded during the pump phase of a grease cycle. The grease pressure may become too high for example, when one of the divider blocks or grease lines becomes blocked or when the viscosity of the grease has become too high (at low temperature).

3.5.2 Low level indicator (optional)

The EcoPlus pumps can be equipped with a low level indicator.If the grease reaches its minimum level the control unit will process, store and report the occurrence of this condition. The pump will disable itself after the maximum allowed amount of grease (150cc after low level) is finished.For example : when 6cc will be delivered per pump cycle. The pump will execute 25 pump cycles before the pump stops (this parameter has to be set during installation).

3.5.3 Over pressure indicator (optional)

The EcoPlus can be equipped with a overpressure indicator.This will give off a visual signal when the pressure in the system becomes to high and the relief valve opens en grease flows back into the cartridge.Example when one of the divider blocks or grease lines becomes blocked, or when the viscos-ity of the grease has become to high.

3.5.4 Manometer

The EcoPlus can be equipped with a manometer.This will represent the current pressure in the pump outlet, this can visually proof the system is working correctly or when the pressure is to high and the relief valve is active.The background of the manometer is coloured with red and green sections so even with out system knowledge, a read out of the system functionality can be made.

Visual pressure indicator with relief valve Manometer with relief valve


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3.5.5 Revolutions of pump drive shaft

As integrated sensor monitors the drive shaft rotations. When it does not sense a rotation the control unit will see this as a error and report it as such. (Rotation counter available in user-in-terface.

3.5.6 Defective wiring and short-circuits

Open-loads (interruptions) in the wiring of the minimum level switch, the electric motor and any signal lamp will be detected and processed and stored by the control unit. This is also applicable to short-circuits in the wiring.

3.5.7 Block switch (optional)

The EcoPlus automatic greasing system can be equipped with a switch for monitoring one or two of the divider blocks (Not on trailer version). When this switch does not change state during a number of successive greasing cycles, this will be indicated on the display and the lamp as a fault.

ATTENTION

Please be aware that at low temperatures it can take more successive cycles to cause a state change of the block switch. In the table below the advised block switch settings at which the system should still be operating is shown.These parameters should be set at an ambient temperature of +15 to +20°C

If a state change is shown each cycle at 20°C and the system should still be operating at 0°C set the block switch parameter to 3. When you operate the system at -10°C this should be set to 5 cycles.

Minimum operation-al temperature

State change each cycle

State change every 3 cycles

0°C 3 9

-5°C 4 12

-10°C 5 15

-15°C 6 18

-20°C 8 24

RemarkMentioned settings are based on a system with the block switch mounted on a divider block and the use of GreenLube EP-2 grease

EcoPlus




3.6 The Divider blocks

3.6.1 Properties

The divider blocks distribute and measure out the grease to the various grease points in a progressive way. That means that all grease points will be greased successively one after another. The divider blocks can be placed in sequence, in which case an output of a divider block is used to feed the next block by a primary grease line.

3.6.2 Composition

1

2 3

A progressive divider block comprises the follow-ing components:

1. A start-segment2. Min. 3 and Max. 12 divider segments3. An end-segment

The divider segments are available in several sizes:Size 1 (2x 0.045cc or 1x 0.090cc)Size 2 (2x 0.075cc or 1x 0.150cc)Size 3 (2x 0.125cc or 1x 0.250cc)Size 4 (2x 0.200cc or 1x 0.400cc)Size 6 (2x 0.300cc or 1x 0.600cc)

Each divider segment always has two grease outlets, with identical grease outputs per cycle. The connections of the grease channels between the divider segments are sealed with O-rings. The divider segments between the start- and end-segment are strung together by two bolts. For each additional divider segment, longer bolts are required.

3.5.8 Signal light (optional)

GROENEVELD 97

6.01

The signal light has to be mounted in the field of vision of the driver and out of direct sunlight, because of the visibility of the signals.When the control units detects an error the signal lamp will be lit continuously. Refer to paragraph 7.6.4 Fault codes by user interface.The signal light resets automatically when a cor-rect cycle has been performed.The signal lamp blinks at low level.


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3.6.3 Principle of operation

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2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

11a

2b

1b

2a

3a

3b

2 3

4 5 6

To operate, progressive divider blocks need grease pressure supplied by the pump:1. The lubricant flows from the entrance of the block, via piston 3, through all segments to the left-hand side of piston 1. When piston 1 is pushed to the right by the grease pressure. The grease at the right-hand side of piston 1 will be pressed to outlet 1a.2. Because piston 1 has now been pushed to the right, the lubricant now flows, via piston 1, from the central input channel to the left-hand side of piston 2. Piston 2 is then moves and supplies grease to output 2b.3. Because piston 2 has been pushed to the right, the lubricant now flows, via piston 2, to the left-hand side of piston 3. Piston 3 is pushed to the right and supplies lubricant to outlet 3b.4. After piston 3 has been pushed to the right, the lubricant is pressed to the right-hand side of piston 1. Piston 1 will move to the left and supply lubricant to outlet 1b.5. Afterwards piston 2 will also be pressed to the left and will supply lubricant to outlet 2a.6. Afterwards piston 3 will also be pressed to the left and will supply lubricant to outlet 3a.7. The divider block then arrives back at its starting-off point and the cycle will repeat .... as long as there is pressure in the primary grease line.

REMARKThe description and illustration above assume there is a fixed starting-off point for the dividersegments in the divider block. This is not so. The divider block always continues fromwhere it left-off during the previous pump phase of the grease cycle.

WARNINGTo be able to operate at all a divider block needs to have at least three divider segments.

EcoPlus




3.6.4 Non-return valves

Non-return valves are installed in the outputs of the divider block to prevent lubricant from flowing back into the divider block. All outlets which are used to interconnect divider blocks must be fitted with non-return valves. Outlets which secondary grease lines are connected on, must also be fitted with non-return valves if significantly high return pressures are expected.

3.6.5 Failure of one of the divider segments

If one of the divider segments fails to operate properly (due to internal or external damage) the whole greasing system will fail to operate.

3.6.6 Closing outputs

An output may only be closed-off after removal of the internal plug(1) that separates the two outputs of a divider segment. Removing the plug allows the grease meant for the close-off to exit through the output that remains open (it doubles the output of the one that remains open). The divider block will become inoperable if the plug is not removed.

3.6.7 Combining outputs

The outputs of a divider block can be combined by installing an external interconnection line(2). The total grease output in that case is the sum of all outputs interconnected.The two outputs of a divider segment can be combined by removing the internal plug that separates the two outputs and closing-off one of the outlets. This doubles the output of the outlet that remains open.

1

1

3

3

4

0.090cc

0.045cc

0.125cc

0.045cc

0.125cc

0.450cc

0.200cc0.200

0.200 0.125

0.045

(2)

(1)

The values in the illustration represent the grease outputs of the ports in cc’s percomplete cycle of the divider block. The amount supplied is determined by the diameter of the piston.

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4. DESIGNING A SYSTEM

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F214317R0120 Designing a system



4.1 Introduction

The following aspects influence the design of a EcoPlus greasing system:

• The number of grease points to be connected.• The position of the grease points on the vehicle or machine.• The grease demand of the grease points.• The greasing interval required by the grease points.• The space available on the vehicle or machine for the pump unit and the divider blocks.• The NLGI class of the grease to be used and the lowest ambient temperature under which

the greasing system is expected to function.

4.2 Points of departure

Pump

Maximum working pressure 275 bar

Piston size see table 1

Number of outlets 1 or 2

Divider blocks

Maximum number of divider blocks in serie 2

Available segment types see table 2

Minimum number of divider segments in a distribution block 3

Maximum number of divider segments in a distribution block 12

Pressure drop in a distribution block, related to see table 3

• The number of segments in the divider block

• The NLGI class of the grease used

• The ambient operating temperatures

Primary and secondary grease lines

Pressure drops in the grease lines see table 4

• The diameter of the lines

• The length of the lines

• The NLGI class of the grease used.

• The ambient operating temperatures

Resistance at the grease point

Ball or roller bearing 5 bar

Slide bearing 15 bar


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Revolution (parameter)

Piston No.30.15cc /stroke

Piston No.40.20cc/stroke

Piston No.50.25cc/stroke

1 0.15 0.20 0.25

5 0.75 1.00 1.25

10 1.50 2.00 2.50

50 7.50 10.00 12.50

99 14.85 19.80 24.75

Segment type Output per segment(2 outputs) (cc) Output with combined outputs (cc)

1 2 x 0.045cc 0.090cc

2 2 x 0.075cc 0.150cc

3 2 x 0.125cc 0.250cc

4 2 x 0.200cc 0.400cc

6 2 x 0.300cc 0.600cc

Table 1: Grease delivery (cc)

Table 2: Outputs of divider segments

Table 3: Internal resistance in a divider block (bar)

Grease class

T [°C] 3 Divider segments 8 Divider segments 12 Divider segments

NLGI 2

+20 14 bar 16 bar 22 bar

+10 28 bar 24 bar 26 bar

0 34 bar 44 bar 55 bar

-10 52 bar 58 bar 72 bar

-15 73 bar 77 bar 100 bar

-20 80 bar 85 bar 170 bar

Table 4 : Grease line resistance (bar per metre)

Grease class

T [°C] PA Ø 3/16 Ø 2.4mm i.d.

PA Ø 6Ø 3.0mm i.d.

High-pressure hoseDN4 Ø4.0mm i.d.

High-pressure hose DN6 Ø6.0mm i.d.

NLGI 2

+20 6 bar 6 bar 6 bar 3 bar

+10 14 bar 8 bar 6 bar 4 bar

0 17 bar 12 bar 10 bar 6 bar

-10 25 bar 18 bar 16 bar 9 bar

-15 34 bar 25 bar 20 bar 14 bar

-20 55 bar 36 bar 30 bar 22 bar

RemarkThe values in these tables were collected during laboratory and field tests and will be supple-mented as new data becomes available.

EcoPlus




4.3 Method

1. Determine the conditions under which the system must be able to operate.2. Make a greasing plan.3. Indicate, in the greasing plan, the grease demand and greasing interval required by each

grease point.4. Compile the greasing points in groups.5. Determine the required layout of the greasing system.6. Check by calculation, whether the system will be able to operate under the conditions

determined during step 1.

4.3.1 Determine the operating conditions

Determine what the lowest expected ambient temperature will be.

4.3.2 Produce a greasing plan

Make a simplified layout drawing of the vehicle or the machine. Indicate the positions of the grease points on that drawing and number them.

4.3.3 Determine the grease demand of the grease points

The grease demand of a grease point over a period of time is determined by grease output per greasing cycle and greasing frequency. This information can be extracted from :

• The maintenance instruction for the vehicle or machine.• Existing greasing plans for class 2 grease systems.• Information provided by the manufacturer, importer,dealer maintenance personal or user.• See tables below.

Description Segment type

Upper king pin 3

Lower king pin 3

Suspension bearing,brake axle (drum side)

1

Upper stabiliser 1

Spring shackle 3

Cabin bearing 1

5th wheel 2 x 6

5th wheel, tilt bearing 2

Tail board cylinder 1


King pin, single grease point 2 x 3

Automatic slack adjuster 1

Suspension bearing(slack adjuster side) 1

Lower stabiliser 1

Spring pin 3

5th wheel locking pin 1

Tail board hinge 1

Support bearing drive shaft 1

Table on road


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Turntable 3

Arm cylinder barrel end 2x3

Arm cylinder rod end 2

Upper tail swing bearing 3

Lower tail swing bearing 3

Swing cylinder barrel end 1

Swing cylinder rod end 1

Stick cylinder barrel end 1

Stick cylinder rod end 1


Stick pivot bearing 2x3

Bucket cylinder barrel end 1

Bucket cylinder rod end 2

Dog bone pin 4

Boom pin (when one point) 4 (2x4)

Bucket pin 2x6

Bottom H link pin 2x4

Upper H link pin per side 2

Table off road (based on a mini excavator with a operating weight till 7,5 tonnes )

4.3.4 Group the grease points

Compile groups of grease points, taking into account the following:• A main divider block or multiple grease outlets on the EcoPlus pump may be utilised.• The maximum and minimum number of divider segments that can be combined in a single

divider block.• The lengths of the primary and secondary lines in relation with the NLGI class of grease that

must be used and the projected operating temperatures.• Any special demands that might be placed on the grease output and the greasing interval

4.3.5 Determine the layout of the system.

Note the positions of the pump unit and the divider blocks on the greasing plan.Determine the required number of pump outlets, composition of the divider blocks, based on the group of grease points to be connected with that block. Indicate the routing of the grease lines on the greasing plan.

Take into account : • The routing of the lines and the type of secondary grease lines that will be used (single or

composite lines with 2 to 3 separate lines)• The possibility to combine the output of divider segments • The minimum (3) and the maximum (12) number of divider segments that can be combined

in to a single divider block.

Calculate the grease demand of each divider block in the system per complete cycle. This is required to determine the parameters in the pump.

EcoPlus




System featuring a main divider block

In a system with more then 2 divider blocks or when the grease ratio between the 2 divider blocks cannot be met with the available pump piston sizes, a main divider block is required.

Determine the composition of the main divider block by:

• Determining the ratios of the grease demands of the divider blocks to be connected to the main divider block.

• Selecting divider segments types for the main divider block with which the ratios are most precisely matched.

• Determining the required grease output (delivery dependent to the piston used in each outlet) of the pump. This is the sum of the grease demands of all the divider blocks con-nected to a pump outlet. (excluding the main divider block)

This value can be used in a later stage to determine the grease output of the pump.

System without a main divider block

In case of a system with 2 divider blocks of which the ratio between the grease requirements of both blocks per cycle can be met with the available outlet sizes of the pump, an extra out-let is preferred above the use of a main divider block.

Determine the lengths of the primary grease lines between the pump unit and the divider blocks(and between divider blocks) and the length of the secondary grease lines between the divider blocks and the grease points. Note those lengths on the greasing plan.Determine the number of non-return valves that must be incorporated into the greasing system.

Checking the system

Before the components of the system are assembled and installed, the projected system should be checked, by calculation against the operating conditions is was designed for.The loss of pressure in the system may not exceed Pp (pp equals 90% of the maximum oper-ating pressure supplied by the pump unit.)

1. Calculate the pressure loss Pv over the divider blocks, under the set operating conditions using table 2.

2. Determine using the greasing plan which grease point is furthest from the pump. Calcu-late , using table 3 the total pressure loss “PI” over that grease line.

3. Determine which type of grease point is connected to this grease line. Determine the resistance “Ps” induced by that type of grease point (see 4.2 Points of departure)

4. Calculate the largest total loss of pressure “Pt” for each outlet by adding the values of the pressure losses in the grease lines, divider blocks and the at the grease point. (Pt = Pv + PI + Ps)

5. Check that Pt < Pp

If the loss of pressure in the system exceeds Pp investigate the following:

1. Is it possible to use a grease of a lower NLGI class ?2. Is it possible to raise the minimum operating temperature requirement ?3. It might be necessary to redesign the system and reconsider whether :

• Is it not better to omit the main divider block by using a extra outlet on the pump.• The layout of the system can be modified to shorten the grease lines or to reconfigure

the divider blocks.• Using a grease line of a larger diameter to reduce the pressure loss.

After the redesign always recalculate the suitability of the system

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5. INSTALLATION

EcoPlus

F214317R0126 Installation



5.1 Overview

To install the Groeneveld greasing system the following tasks must be performed:

1. Mounting the pump with integrated control unit.2. Mounting the progressive divider blocks.3. Mounting the primary grease lines (between pump and divider blocks and between the

divider blocks themselves.4. Mounting the secondary grease lines and couplings.5. Mounting the electrical wiring.6. Testing of the system.

5.2 Safety precautions

1. Take the necessary precautions to prevent potentially dangerous situations from occur-ring during installation, checking and maintenance.

2. Always apply or use adequate safety measures to prevent bodily harm and damage before you start working.

3. Ensure that the machine is immobilised before you start work. Therefore remove the ignition key and store it in a safe place.

4. Pay special attention to blocking parts such as dipper arm. Make sure that it is safe to work under these parts and that they cannot drop down.

5. Never work underneath a machine that is raised by a jack only. Always use a trestle and check that the ground is firm and flat enough.

6. Disconnect the earth-clamp from the battery. This prevents electrical equipment being inadvertently activated.

7. Adhere to all regulations, specifications and limitations as specified by the manufacturer of the machine.

8. Use only clean tools that fit and are designed for the specific task you want to perform with them.

9. A machine may only be operated by those who are competent to do so and aware of all possible dangers. If necessary, an expert should be consulted.

10. Keep the working area clean and tidy. This enhances safety.

5.3 General installation directives

1. Check the contents of the parts kit using the parts list included in the kit.2. Before start installing the greasing system, check that all the grease points are open and

furnished with a sufficient amount of grease. If that is not the case, grease the grease point by hand. This prevents insufficient greasing of the grease point during the period following the first greasing cycles of the greasing system.

3. Apply Teflon tape, or another type of sealant (e.g. Loctite), to the coupling and plugs, if not already fitted with O-rings,gaskets or sealing rings. While mounting the couplings and plugs, make sure that the tape does not cause internal contamination of the system.

4. Prevent any contamination of the system during installation. Use clean tools and clean the locations on the machine where the pump unit and other parts are to be installed. Even small contamination can cause the greasing system to malfunction. Flush the primary grease lines after installation or maintenance, if contaminations or moisture could not be prevented from entering the system. The de-aerate procedure may be used to flush the system.


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5.4 Mounting the pump unit

1. Determine jointly with the client where the pump unit should be mounted, if this is not already indicated in machine-specific installation instructions. Make sure that:• The pump unit is easily accessible for replacing the cartridge.• The grease level is easy to inspect visually.• The pump unit is protected against possible damage.

2. Investigate whether existing holes of the machine can be used to mount the mounting plate of the pump unit. Always follow the directions of the machine manufacturer when you need to drill holes. Be sure not to damage anything (e.g. lines or wires) that may be present behind the part in which you drill a hole. After drilling a hole, always remove the swarf (with compressed air).

3. If the mounting plate is to be welded onto the machine, the directions of the machine manufacturer should be strictly adhered to.

4. Mount the mounting plate with the pump unit onto the machine.5. Remove the transport plugs from the grease outlet.6. Mount the couplings for the primary grease lines onto the outlet of the pump unit.

5.5 Divider blocks

5.5.1 General

The composition of a progressive divider block is always machine/vehicle specific. If the divider blocks are part of an installation kit the divider blocks will usually be pre-assembled including the secondary lines.

5.5.2 Assembly

The Divider block must be assembled before it can be installed on the vehicle/machine.To ensure the reliability of the greasing system, the divider blocks should be assembled in a clean, dust-free environment.

The criteria that governs the composition (number and type of divider segments) of a divider block are discussed in the Designing a system (4) section of this manual.

5. During installation of grease hoses and electric wires, ensure that:• The hoses and wires are not fastened to or near hot parts such as exhaust, turbo or air

conditioning unit.• The hoses and wires taut and fixed in place with small or large straps or clamps.• The hoses and wires are not installed alongside moving parts in such a way that they

may become damaged (in time).• The hoses and wires have a sufficient length, particularly if they are laid to moving

parts. Check this by shifting the moving parts to its extreme positions.• Ensure that grommets are used wherever there is a chance of a hose or wire being

damaged.6. Check whether the machine voltage corresponds to the voltage required for the pump

in the kit.

EcoPlus




1. First study the drawing of the divider block to be assembled.2. Check whether all required components are at hand and whether the right couplings for

the right kinds of secondary grease lines are available.3. Begin by placing the start-segment onto the work bench with the port for the primary

grease line facing downwards.4. Place, in the order as indicated on the drawing the various divider segments on top of

the start segment. Place the end segment at the top of the stack. Ensure that all the openings in the segments are lined-up and check that the required O-rings have been correctly placed between all segments.

5. Place (using two serrated lock washer) the compression bolts through their respective holes. Tighten the two bolts alternately and in phases (Allen key : 5mm) Torque 12 Nm

6. If the two outlets of the divider segment need to be combined , remove the internal plug that separates the two outlets (Allen key 2.5mm). The grease output of the port that remains open will then be double its normal output.

7. Mount the couplings, non-return valves and plugs into the outlets of the divider blocks, as indicated on the drawings.

8. Mount the secondary grease lines.9. Connect the grease pump or manual grease gun to the port of the primary grease line to

test the operation of the divider block and check for leakage.

5.5.3 Mounting

Determine the location of the divider block on the vehicle/machine. Consult the specific installation instruction manual (if present) and take account of :• No stresses may be present in the mounted divider block. Its best to use mounting brackets

to install the divider blocks.• The divider blocks should not be installed near to moving parts.• The divider blocks should not be installed near parts that become hot (e.g. turbo charger,

exhaust.• Existing mounting holes in the chassis should be used whenever possible.

The divider blocks can be mounted with a mounting bracket in two ways:

1. First mount the brackets. Then mount the distribution block onto the brackets. This method is compulsory if the brackets are welded on the vehicle or machine.

2. First mount the divider block onto the bracket. Then mount this assembly on the vehicle/machine.

Which method is preferred depends on the manoeuvring space available.

Attention

Always apply serrated lock washers to the M5 mounting nuts and bolts of the divider blocks. Tighten the bolts alternately and evenly. Maximum torque 5 Nm.

5.6 Primary grease lines

The primary grease lines are situated between the pump and the divider blocks and/or be-tween the main divider block and divider blocks.The most common line used in EcoPlus installation is DN4. This high quality hose combines compactness with high strength and flexibility


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5.6.1 Line types

• High pressure hose DN4 : F123414, Diameters inside 4.0mm, outside 9.7mm;• High pressure hose DN6 : F113422. Diameters inside 6.0mm, outside 12.0mm;• Metal tube with sizes Ø 6x1mm or Ø 8x1mm;

5.6.2 Crimp diameter

• Ferrule DN4 : F115331 crimp diameter 9.95 - 10.1mm• Ferrule DN6 : F113941 crimp diameter 14.8 - 15.00 mm

5.6.3 High pressure hose assembly

1. Cut the length of the hose to the required length;2. Remove any burrs and other remnants produced by cutting the hose and clean the

grease hose by blowing it through.3. Assemble the removable fitting or crimp fittings.4. Fill the hose with grease. (if not pre-filled) with either a pneumatic or hand operated

grease gun;5. Install the hose and fix it into place with cable ties or clamps. Don’t connect the primary

hose to the pump outlet yet, if you want to use a pneumatic or hand operated grease gun to de-aearate the system.

Removable fittings

1. Clamp the ferrule in a vice;2. Turn the hose counter clockwise into the ferrule till the end;3. Turn the hose clockwise 1/4 up to 1/2 a turn;4. Apply oil or grease to the insert, the ferrule and the inside of the hose;5. Turn the hose insert clockwise in the ferrule until it’s in position without tension;6. Mount the coupling at the other end of the hose in a similar way.

Crimp fittings

1. Check if the press holds the correct die set for the required ferrule diameter;2. Slide the ferrule over the hose until the end.3. If necessary use some oil and slide the insert into the end of the grease hose until the

insert is completely in the hose.4. Pull the ferrule back slightly until it touches the outside edges of the coupling pin.

While doing this, ensure that the insert remains in place and is not pressed out of the hose;

5. Place the assembly into the press and use the press to crimp to the required diameter;6. Check the resulting outside diameter by measuring the insert with a calliper.(only possi-

ble for straight inserts)7. Mount the crimp fitting at the other end of the grease hose in a similar way.

EcoPlus




5.7 Secondary grease lines and couplings

5.7.1 Grease line types

The secondary grease lines are the ones between the divider blocks and the grease points. These grease lines are connected to the grease points with the aid of a special couplings. A wide variety of couplings are available.

Which types of couplings should be applied, depends among other things, on :• The screw thread at the grease point.• The position of the grease point.• The direction in which the grease line approaches the grease point.• The type of grease line used (poly-amide lines with brass or steel couplings;metal lines or

high-pressure lines with steel couplings).• The operation conditions.

The secondary grease lines can be supplied in a number of different sizes and materials;• Poly-amide lines with outside diameter of 6mm (standard),• Stainless steel lines with the outside diameters of 6 mm (standard).• Cunifer lines with a outside diameter of 6 mm (standard)• High-pressure hoses with inside diameters of 4mm or 6mm (5/32” and 1/4”)

The type of secondary grease lines commonly used in transport and off-road applications is the poly-amide lines with a outside diameter of 6mm. These grease lines are also supplied as composite lines. In a composite line 2 or 3 poly-amide lines are held together by a single plas-tic jacket. Each grease line in such a composite line has its own colour (red,blue,black), so that they can easily be distinguished at the ends of the composite line (this is useful for during installation and maintenance).

If a composite line is connected to a divider segments with different grease outputs, the indi-vidual grease lines should be connected as follows.• Divider segments with the lowest output Red line• Divider segments with the highest output Black line• Divider segments with intermediate output Blue line.

5.7.2 Installing the secondary lines

Pay attention to the following points during the installation of the secondary lines and cou-plings:• Always make sure the thread on the couplings and the grease points are identical.• To identify them, elbow couplings with metric thread are marked with a “M”. Straight cou-

plings with metric thread have a groove on there hexagons.• Always apply a spacer between the airlines for the brake actuator and grease lines when

routing alongside them. This prevents the airlines for the brake actuator from damage due to the use of cable ties and friction from the grease line.

• Never add extra grease points off you own accord. The integrity of certain structures may be adversely affected by drilling holes. Always adhere to the relevant directive issued by the vehicle manufacturer.


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If a vehicle specific greasing plan is available, the types (or combination) of couplings to 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 couplings. If the grease point to be connected is a so-called “added” grease point a hole must be drilled and threaded with the same thread as the required coupling.Do not forget to clean the new hole of any debris. Mount the required coupling in the grease point(see greasing plan). Make sure that elbow couplings point in the direction of the grease line. Avoid unnecessary (sharp) corners in the grease line.

Attention

Always check that the newly drilled grease point is open by applying a grease gun to it.

1. Determine the most suitable route for the grease line to the grease point.2. Cut the grease line at roughly the required length.3. Determine approximately , the required length of the individual grease lines in a com-

posite line.4. Strip and remove the outer jacket over this length. Make absolutely sure that you do not

damage the individual grease lines.5. Fix the lines in place with cable ties or clamps up to the coupling at the grease point.6. Cut the individual grease lines to the required length and connect it with the coupling to

the grease point.

5.8 Electrical wiring

Detailed wiring diagrams are available as aids to install the electrical wiring. Where possible, pre-assembled wiring harnesses are delivered.

ATTENTION

In order to avoid damage to the electrical system of vehicle or machine, the correct fuses must be installed in the power supply circuit. Consult the table below or the wiring diagrams for the correct fuse ratings.

• Connect the wires only when the main components (pump unit, signal lamp and optional hammer shut-down valve or relay) have been installed.

• Lay the wiring as far as possible along the passage of the existing electrical wiring and fas-ten them with small or large straps.

• Always make wire connections in the cabin or in a watertight terminal box.

5.8.1 Fuse ratings

Voltage Fuse (pin 1) Fuse (pin 3 trailer mode)

Fuse type

12 Vdc 15 A 15 A Slow acting automotive fuse

24 Vdc 10 A 10 A Slow acting automotive fuse

EcoPlus




5.8.2 Pin layout of the connector on the pump unit

Truck version

Connector pin number

Description of connection Diameter {mm2} Wire colour in wiring harness

1 Supply voltage (+15) 2.50 Red

2 Ground (-31) 2.50 Black

3 Input A (-) 0.75 Green

4 Input A (+) 0.75 Orange

5 Input B (-) 0.75 Pink

6 Input B (+) 0.75 Purple

7 Lamp output (-) 0.75 Light blue

8 Lamp output (+) 0.75 Grey* Input A = Block switch* Input B = Block switch or command input.

Trailer version

Connector pin number

Description of connection Diameter {mm2} Wire colour in wiring harness

1 Brake light (+) 2.50 Green

2 Ground (-31) 2.50 Black

3 Tail light (+) 2.50 Orange

4 Lamp output (-) 0.75 Light blue


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85 87 87a

30

-31

+30

A

86

+15

Blac

k

Red

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Gre

en

Ora

nge

Pink

Purp

le

Blue

Gre

y

Black

Red (1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Green

Orange

Pink

Purple

Blue

Grey

Led*

Fuse

22K

22K

A B

12v : 15 Amp24v : 10 Amp

Block switch*Block switch*

* =Optional

Truck version

EcoPlus




85 87 87a

30

-31

+30

A

86

+15

-31

Blac

k

Red

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Gre

en

Ora

nge

Pink

Purp

le

Blue

Gre

y

Black

Red (1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Green

Orange

Pink

Purple

Blue

Grey

Led*

Fuse

22K

A -

12v : 15 Amp24v : 10 Amp

Block switch*

* =Optional

Cmd input**

**Commando input :Only possible to connect a ground to start/stop the timer.

Truck version with command input


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BL = Brake lights

TL = Tail lights

Blac

k

Blue

(1)

(2)

(3)

(4)

Gre

en

Ora

nge

Black

Blue

(1)

(2)

(3)

(4)

Green

Orange

Led*

TL

* =Optional

BL

+

*

++

Trailer version

EcoPlus




5.9 Bleeding the system

The system has been properly de-aerated when a closed collar of fresh grease is present at all connected grease points.

Proceed as follows:

• Disconnect the grease hose from the pump.• In order to avoid soiling of the workplace, place a beaker or plastic mug under the grease

outlet port of the pump.• Switch on the power of the machine.• Start a multiple test by selecting this in the diagnostic menu. (or set interval to 1 Min and

delivery to 20 rotations, this will cause the pump to continuously run) • Allow it to run until a continuous stream of grease emerges from the pump outlet port.• When air bubbles no longer appears, the pump motor can be switched off by switching off

the ignition (or setting the interval and delivery back to original settings)• The grease hose already filled with grease can be connected to the pump again.• Then switch on the pump motor again.• Start a other test cycle • Check whether grease comes at the grease points. This can take a short time because a cer-

tain pressure first has to be built up before the grease at the end of the grease hose starts to move.

• When the grease starts to come out of the grease point, the pump motor can be switched off.

• The EcoPlus system is now completely free from air.

5.10 Commissioning of the greasing system

The switch on the ignition (+15) and check that the user interface becomes active (also check the signal light if connected). In doing this you ensure that the voltage and ground connec-tions are correctly connected, the fuse has not blown( and the signal lamp is OK).Now check the desired system parameters.

• The status of the remaining interval time or pump revolutions is visible on the status screen.

• Whether errors are stored in the error menu. It is possible, however, that a minimum level in the grease reservoir (“low level”) of an interrupted lamp circuit (“OL lamp circuit”) error is stored due to the fact the voltage to the pump was switched on at a time when, for exam-ple, the grease cartridge had not yet been fitted or that the signal lamp was not yet con-nected. Always check whether such errors in the error counts or indication counts groups disappear after a correctly performed cycle.

• Check the system one last time for leaks. If leaks are found, remedy these and thoroughly clean the area of the leakage so that the client does not get the impression that the system is still leaking.

• Explain and demonstrate the function of the system to the client or machine dealer, if pres-ent.

• The system is now ready for operation.


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5.11 Performing a test cycle

A test cycle can be performed by using the user interface, as follows:

1. The supply voltage for the pump unit must be available (ignition ON).2. Enter the main menu by pushing any button twice, scroll down to Diagnostic menu and

press select, press select again to start a single test.3. This start one greasing cycle.

To end the test cycle immediately switch the ignition off. Any errors that occur during the test cycle will not be indicated by the signal lamp and will not be stored in the memory bank of the control unit.

ATTENTION

When the pump unit is already performing a pump phase, a test cycle cannot be performed in this way.

EcoPlus




Notes

39F214317R01 Maintenance

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6. MAINTENANCE

EcoPlus

F214317R0140 Maintenance



6.1 General

The maintenance of the Groeneveld EcoPlus system can be combined with the normal main-tenance of the machine.

WARNING

If a high-pressure steam/water jet is used to clean the machine, the pump unit should not be directly exposed to the jet. This to prevent water from entering the pump unit through its de-aerating opening. During normal operation, however, water will never be able to enter the pump unit.

ATTENTION

The automatic greasing system reduces the time and effort spent on manual greasing significantly. However, do not forget that there may be greasing points that are not served by the greasing system and must still be greased by hand.

6.2 Regularly checks of the greasing system

Check the following points of the EcoPlus greasing system:

1. The grease level in the cartridge of the pump unit (replace in time).2. The pump unit for damage and leakage.3. The operation of the whole greasing system. Perform a test cycle.4. Retrieve the error codes stored in the memory bank of the control unit, by using the user

interface 5. The primary and secondary grease lines for damage and leaking.6. A collar of fresh grease should be present alongside the outside of all grease points.

41F214317R01 Maintenance

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6.3 Replacing the grease cartridge.

The EcoPlus pump is fitted with a grease cartridge. The cartridge is placed under a cover and is easily and quickly replaced.

ATTENTION

When replacing the grease cartridge, prevent dirt from entering the pump. Before removing the cover and the cartridge, first clean the pump and its immediate surroundings. When removing a cartridge that is not completely empty be aware that grease can drip out of the cartridge. Protect the environment and prevent grease spills. Empty cartridges and grease residues must be disposed off in accordance with local regula-tions.

1. Turn the cover with bayonet catch counter-clockwise and lift it off the pump;2. Turn the empty cartridge with rubber gasket counter-clockwise and lift it straight up;3. Check to make sure the sealing ring is remove with the old cartridge;4. Remove the cap from the new cartridge5. Put a film of grease onto the ring of the cartridge.6. Screw the cartridge clockwise onto the pump;7. Reuse the magnet ring if the pump is equipped with a low level indicator, slide the mag-

net ring over the first ridge of the cartridge,make sure the ring is positioned correctly;8. Clean the cover and place it on the pump then turn it clockwise until locked.

65

CB

A

4

A

B

321

EcoPlus

F214317R0142 Maintenance



6.3.1 Wiring diagram

1. Pump unit.2. Control unit.3. Pump motor.4. Revolution sensor.5. Minimum level switch.6. Battery of the machine.7. Ignition switch.8. Signal light.9. Input B (block switch / input command )10. Input A (block switch)

Attention

When using the command input pin 6 is not connected: the switch needs to be to a ground signal on pin 5 (see page 29)

1

8

7

6

5

4

3

2 GND

+15

Low

J3

J1

J2

J5J4

Ground

Output Signal

Vdc

PUMP- +

lgn

+-

B

A

1

2

3

45

7

6

8

9

10

43F214317R01 user interface

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7. USER INTERFACE

EcoPlus

F214317R0144 user interface



7.1 Introduction

The EcoPlus has a display with a user interface on the pump unit, this removed the need for expensive diagnostic tools to change parameters and read out information and fault codes.

Representation of the screens is dependent on the software version, pump version and settings made.

7.1.1 Function keys

The EcoPlus has a keypad with three function keys to navigate the user interface, the com-mands per key can change per menu. Most common commands are Up,Down and Select.

By pressing the left and middle key simultaneously the program will go back one level.

7.1.2 Commands

Abbreviation Meaning

Up Increases the value selectedDown Decreases the value selectedSelect To confirm the selectionSave Store a settingCancel Stop the planned actionClear Resets a counterPrev Go to previous screenNext Go to next screenList Go to the current menu list


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7.1.3 Access levels

In the user interface you have access to parameters and diagnostic information.There are two access levels in the user interface.• Basic, this is the normal operating mode of the EcoPlus and will give access to all the basic

functionalities.• Supervisor mode, this is for the mechanic to set specific parameters and diagnostic informa-

tion.When a ‘S’ is shown in the upper right corner of the screen,this means that the ‘Supervisor’ mode is active.

7.1.4 Accessing Supervisor mode

Only access supervisor mode when you are familiar with the EcoPlus sys-tem and have had the required technical training.

Changes made in the parameters are stored in the memory

Take the following steps to get access to the supervisor mode.• Make sure you are in the Main menu• Press the outer two buttons on the keypad simultaneously <Up> and <Select>• Hold these down for a period of two seconds.• The release and press and hold the middle key <Down> with in two seconds of releasing

the outer keys, hold the key down until “S” appears in the top right corner (flashing)

7.2 Main menu

The main menu:• Information: informs about the pump data• Parameters: to set and check the parameters• Diagnostics: to preform tests and read out errors.

EcoPlus

On power on the display becomes active.The start up screen is shown shortly.

• When programmed to trailer version this screen is not shown

On normal power-up the pump goes to status screen, with no back-light.EcoPlus

.--- Menu ---.

Interval9

min

Main Menu

Up Down Select

InformationParametersDiagnostics

i

EcoPlus




7.3 Information menu

Select the information menu, by moving the cursor this is done by pressing <Up> or <Down> until the Information tab is highlighted.Then press <Select>

Main Menu

Up Down Select

ParametersDiagnostics

i Information

• On-time hrs: Total hours the greasing system has been operating.

• Pump cycles: The total preformed pump cycles.• Total rev: The total motor revolutions made.

Information

Up Down Select

Pump cyclesTotal rev

i On-Time hrsii

• Total test: Total test cycles preformed.• No Pwr-on: The total times the pump was powered.• SW version: The software version in the PCA.

Information

Up Down Select

No Pwr-onSW version

i Total testii

• Serial no: Shows the serial number of the PCA. The serial number of the pump is show on the identification plate on the side of the motor cover.

• Back: Goes back to the main menu.

Information

Up Down Select

Backi Serial No

i


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7.4 Parameter menu

Select the parameters menu, by moving the cursor this is done by pressing <Up> or <Down> until the parameter tab is highlighted.Then press <Select>

Main Menu

Up Down Select

Diagnostics

i InformationParameters

• Interval: Sets the time between grease cycles in minutes Default : 180 minutes; Range : 1-300 minutes

• Delivery: Sets the number of revolutions of the pump motor per grease cycle.

Delivery is depended on the outlet used. Standard outlet used is No.5 = 0.25cc per revolution.

Default : 10 revolutions (10 x 0.25cc = 2.5cc per cycle)

• Display: Enters the display sub-menu.

Parameters

Up Down Select

DeliveryDisplay

i Interval

The Display sub menu contains the following parameters;

• Light on: The percentage of light when the display is active. Default: 90%; Range 0 - 100%

• Light dim: The percentage of light when the display is in-active. Default: 25%; Range 0 - 100%

• Contrast: Sets the contrast of the display. Default: 10 units; Range; 0 - 20 units.

Display

Up Down Select

Light dimContrast

i Light on

In the trailer version of the EcoPlus the light on and light dim percentage is set to 0% to prevent flashing of the screen from using the power on from a brake input

EcoPlus




• Block sw A: The number of greasing cycles in which min-imal 1 state change of the optional block switch needs to be detected in order to prevent the error from being activated.Default: 0 (=off); Range: 0 - 29 cycles)An optional block switch monitors the piston movement of a divider block during a single or number of greasing cycles. A piston movement indicates that grease from the pump is still passing through. (see page 10)

Parameters

Up Down Select

Block sw Blow Lvl

i Block sw A

• Block sw B: see Block switch A for explanation.• (Parameter no Available is CMD input is activated)• Low lvl: set this option to “On” when low level switch is

connected. The PCA will ignore info from the low level sensor if this is not activated. Default: depended on model EcoPlus

Parameters

Up Down Select

Block sw Blow Lvl

i Block sw A

• Pump stop: To enter the allowed number of pump cycles to be preformed after reaching low level.(Parameter not available if Low lvl is set to “off”

Default: 50 cycles; Range: 0 - 200 cycles.

Low level warning will become active when approx-imately 150 cc grease is left in the cartridge, use the pump delivery to calculate the correct number of cycles.

Example : 10 revolutions (10 x 0.25cc = 2.5cc per cycle150 cc : 2.5cc per cycle = 60 cycles.

• Lamp output: Set this option to “On” when a lamp is connected to the output.Default: On, Range: On or Off

Parameters

Up Down Select

Lamp outputTrailer

i Pump stop

The following parameters can only be set in supervisor mode, Only access these if you are familiar with the EcoPlus system and have had the required technical training.

Changes made in the parameters are stored in the memory

In the trailer version of the EcoPlus block switch A and B are not available.


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• Trailer: This sets the trailer mode to active in the soft-ware, this changes the behaviour of several inputs and adds and removes certain menu options in the interface.

Trailer

On O� Select

i Trailer o�

• Dual input: This sets the timer to accept power on pin 1 and pin 3 of the harness.Default: Off, Range: On or Off

Pin 1 = Break light Pin 3 = Tail light

• Timer & Cnt: Set this to “On” is you want to use both the break counter and a interval timer to start a grease cycle, both counters reset if a cycle is started.Default: Off, Range: On or Off

Trailer

Up Down Select

Dual inputTimer & Cnt

i Trailer

7.4.1 Trailer sub-menu

Trailer mode will only be active on trailer pump, its not possible to use the trailer option in truck versions of the pump.

• Brake time: This sets the amount of time the break pulse needs to be active on pin 1 for it to count for the timer. This to avoid rapid pulsing breaking to start a cycle to early.Default: 0.5sec

• Back: goes back to the Parameter menu.

Trailer

Up Down Select

Backi Brake time

• When the pump is set to trailer mode, this is visible on the status screen during normal operation by the addi-tion of Tr after the EcoPlus name.

• Also the interval will be show in Breaks left before cycle (or switching between breaks and minutes when “Timer & Cnt” is set to “On”

EcoPlus Tr

.--- Menu ---.

Interval 9Brks

EcoPlus




7.4.2 Cmd input sub-menu

Cmd mode can only be active on truck pump, its not possible to use the Cmd option in trailer versions of the pump, and will not be show if trailer is active

• Ci activate: This sets the timer so it starts counting down the interval time when a signal (ground) is put on pin 5. (block switch B will no longer be available) Default: Off, Range: On or Off

Cmd input

On O� Select

i Ci activate o�

• Ci invert: This inverts the function of the of the com-mand input, when invert is on the timer now stops when a signal(ground) is put on pin 5 Default: Off, Range: On or Off

Cmd input

On O� Select

i Ci invert o�

• When the pump is set to command input mode, this is visible on the status screen during normal operation by the addition of Cmd after the EcoPlus name.

• If the interval time is not counting down, this is shown on the stats display. This will return to interval when the timer is running.

EcoPlus Cmd

.--- Menu ---.

stopped 9min


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7.4.3 Example of changing a parameter

How to set the interval time.

• In the “status” screen press <any key> twice to get to the main menu

EcoPlus

.--- Menu ---.

Interval9

min

• In the main menu, Press <down> once until “Parameters” is highlighted, then press <Select>

Main Menu

Up Down Select

Diagnostics


• Press <Up> or <Down> until the desired parameter is highlighted and press select. For this example we use Interval.

Parameters

Up Down Select

DeliveryDisplay

i Interval

• In the interval parameter there are three digits visible that make up the units to be set in minutes.

• Press <Up> or <Down> to change the value then press <select> to go to the next digit.

Up Down Select

i Interval

180 Min Max: 300Min: 1

• After the last digit is selected, the user gets a confirma-tion screen, with the entered value.

• Press <Save> to accept this as the new value.• Press <Cancel> to decline the new setting and the cur-

rent (old) parameter will be used.• Both action will result in going to back to the Parameter

menuSave Cancel

i Interval

180 Min Confrim?

EcoPlus




7.5 Diagnostics menu

Select the diagnostics menu, by moving the cur-sor this is done by pressing <up> or <down> until the parameter tab is highlighted.Then press <Select>

Main Menu

Up Down Select

Diagnostics


• Single test: Starts a Single test cycle, one time the pump revolutions set in the delivery parameter.

• Multi test: Starts a Multiple test cycle, ten times the pump revolutions set in the delivery parameter cycle.

Diagnostics

Up Down Select

Multi testErrors

i Single test

X

• When in a Multi test the display will show this, and count down the remaining revolutions.

• When trying to change the delivery when the pump is in a test cycle, it will say “busy” on the screen. User needs to wait or cancel the test cycle before changing param-eters.

• Cancel any test cycle, by switching the power off.

EcoPlus

.--- Light ---.

Multi test108

Revs

iPumping

• Pending: The current errors of the system (also visible as a warning on the status screen)

• Total: The number of times an error has occurred since the installation of the pump.

• Successive: The maximum number of times an error has occurred in consecutive cycles. The value is only overwritten if a new sequence of errors is larger then the preceding sequence.

Up Down Select

Total

Errorsi Pending

XXX

Successive

7.5.1 Errors

In the Errors sub menu, the errors are subdivided into three categories; pending, total and successive errors. In this paragraph the screens of the total errors are shown and explained.

Note : pending errors are also shown on the status screen of the displayNote : total errors can be cleared in supervisor mode.


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• Low level: The low level switch indicates the grease level in the cartridge is low and would need to be changed soon

• Empty: Pump stopped because the set amount of allowed cycles has been exceeded, no grease left in cartridge.

Up Down Select

Empty

Totali Low level

XXX

No �ow A

• No flow A: Block switch A did not change state at least once during the set number of cycles in succession making it uncertain whether grease is still flowing from the divider block(s)

• No flow B: same as A only for the second input• Timing: The set number of rotations per cycle exceed

the set interval time. Hence the pump is constantly pumping, please check settings.

Up Down Select

No �ow B

Totali No �ow A

XXX

Timing

• Over voltage: The maximum voltage was detected, the system will shut down to protect itself.

• Low voltage: The voltage was to low for the system to function and the system has shut down.

• Pump short circuit: A short circuit was detected and the attempted cycle was aborted.

Up Down Select

Low volt

Totali Over volt

XXX

Pump-SC

• Pump over current: A current above the maximum allowed has been detected and the attempted cycle was aborted.

• Pump open load: Open circuit detected to the pump motor.

• Lamp over load: a high current on the lamp circuit was detectedUp Down Select

Pump-OL

Totali Pump-OC

XXX

Lamp-OL

• Parameter checksum: The control unit encountered corrupt parameter data and restored to its default values, these do not guarantee a correct function of the system. An error will be generated

• System fault: The control unit detected a corruption in the software of the system, Changing the control unit will most like be necessary

• Back: Return to the diagnostics menu.Up Down Select

System

Totali Param CSXX

Back

• Error time: When pressing next while reading out a error, it will go to the error time screen, showing you the time the fault has been active in seconds.

Prev Next

iTime low levelX

256 sec

EcoPlus




7.5.2 Inputs sub-menu

In the inputs sub-menu, the user can test the functioning and state of the inputs.

Diagnostics

Up Down Select

Backi Inputsi

• Low level: Allows you to test and see the current state of the low level switch

• Input A: Allows you to test and see the current state of Input A.

• Truck pump A = Block switch• Trailer pump A = Brake input

• Input B: Allows you to test and see the current state of Input B.

• Truck pump B = Block switch B or Cmd input• Trailer pump B = not used.

Inputs

Up Down Select

Input AInput B

i Low levelii

• Low level: Allows you to test and see the current state of the low level switch.

• 0 : sufficient: the magnetic ring of the cartridge is high so it doesn’t make contact with the switch.

• 1: low: the magnetic ring of the cartridge is low so it makes contact with the switch.

Prev Next

Low level0= su�cent1= low

i

0List

Select the inputs sub-menu, by moving the cursor this is done by pressing <up> or <down> until the parameter tab is highlighted.Then press <Select>

• Input A: Allows you to test and see the current state of Input A

• 0: input not active.• 1: input active.

• Screen for input B is the same.Prev Next

Input A0= Input low (-)1= Input high (+)

i

0List

Truck version • A= Block switch A.• B= Block switch B or Cmd input.

Trailer version

• A= Brake input• B= not connected on trailer pump.

REMARKThe input A and B represent different functions depending on the model and connection of the pump. Knowledge of the system is required to fully utilise the input screen. Below are the functions possible.


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7.6 Trouble shooting

The greasing system is equipped with an electronic control unit with a memory bank. All rele-vant data concerning the functioning of the greasing system are stored in that memory bank. This data can be read out.

7.6.1 Recognizing malfunctions

Malfunctioning are recognizable or discovered as follows:

• The signal light no longer lights up when the ignition is switched on.• The signal light shows a malfunction.• The status screen give a error warning• Reading the errors saved in the memory of the control unit.• The grease level in the pump no longer decreases.• When visually checking the grease point, it appears that no fresh grease collar is present.

7.6.2 General malfunction reportsProblem Cause Solution

Signal light does not light-up after ignition was switched on.

No supply voltage (+15) on pin no.1 or at signal lamp.

No ground (-31) potential on pin no.2.

Signal light defective.

Wiring to the pump unit or to the signal light defective.

Check the fuse and, if required, replace the fuse.

Check the ground connection and if required repair it.

Replace the bulb or LED.

Check the wiring and, if re-quired, repair it.

Signal light flashes Low grease level in the car-tridge

Replace cartridge

Signal light ON continuously. Empty grease reservoir, pump stopped

Persistent system error.

Replace cartridge.

Retrieve fault by using the user interface and repair the system.

The greasing points connected are too dry, but no malfunction is indicated.

The grease output (cc) and/or the interval time is not set correctly for the current appli-cation.

Increase the grease output and/or set a shorter interval time.

Too much grease has been applied to all grease points

The grease output (cc) and/or the interval time is not set correctly for the current appli-cation.

Decrease the grease output and/or set a longer interval time.

One or more grease points are too dry while others received the correct amount of grease.

Improper composition of the divider blocks

Change the composition of the divider blocks.(recalculate the system)

REMARKFor setting and reading out the parameters of the control unit the user inter-face is used. The user interface can also be used to consult a list of faults that have occurred and were stored in the memory of the control unit.

EcoPlus




7.6.3 Error codes by signal light

The signal lamp blinks when the cartridge has a low level, and is continuously on when car-tridge is empty or any other error.

For locating the cause of errors always use the user interface on the pump.

NOTEThe signal light resets when the problem has been resolved.

7.6.4 Error codes by user interface

• Cause: • Grease in the cartridge reached the level where it

activates the low level switch. (approximately 150 cc grease is left in the system)

• Solution: • Replace the cartridge (paragraph 6.3) Warning

and lamp reset automatically when cartridge is replaced.

EcoPlus

.--- Light ---.

Pumping7

Rev

Low level

• Cause: • Pump is disabled because the cartridge is empty,

the maximum allowed cycles with a active low level was reached, and the pump is disabled

• Solution: • Replace the cartridge (paragraph 6.3) Warning

and lamp reset automatically when cartridge is replaced.

EcoPlus

.--- Light ---.

Pump stopCartridge

Low level

Empty

• Cause: • The set interval time has passed before the end of

the current pump cycle, causing the pump to be continuously pumping

• Solution: • Check the parameter interval time and pump revo-

lutions.

EcoPlus

.--- Menu ---.

Timing fault9

RevsPumping

Timing fault

• Cause: • Block switch A or B did not change state at least

once during the set number of pump cycles, mak-ing it uncertain whether grease is still reaching the divider block. (not possible on Trailer pump)

• Solution: • Check the primary grease lines for leakage.• Check grease delivery pump• Check block switch functionality

EcoPlus

.--- Menu ---.

No �ow A9

RevsPumpingiX

No flow A - B


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• Cause: • The motor runs more slowly then normal.

• Solution: • Grease temperature can be very low and the pump

has difficulty greasing. No action will be needed.• Piston for the pump outlet is mounted wrong and is

blocking the rotation of the motor, check outlet and reinstall correctly

• Check internal wiring of the pump motor

EcoPlus

.--- Light ---.

Slow motor

• Cause: • Power supply voltage exceeded 32 Volt, outputs will

be disabled to protect the system.• Solution:

• Check power supply

EcoPlus

.--- Menu ---.

IntervalX SYS ERR: 1

Slow motor

System error 1 = Over voltage

• Cause: • Faulty battery (vehicle) below 9 volts• Faulty wiring (ground)• Corroded pin-contacts in connector(s).

• Solution: • Charge or replace battery.• Check wiring. Replace or repair when necessary.• Check connections at pump and in cabin. Replace

or repair when necessary.

EcoPlus

.--- Menu ---.


System error 2 = Low voltage

• Cause: • Control unit detected a too high current draw to

pump motor and aborted the attempted cycle, caused by:

• Drive shaft blocked• Extreme low working temperatures in combination

with a grease not suitable for these conditions.• Solution:

• Check pump cam shaft or pistons on damage or blockage and repair or renew pump section.

• Replace the grease in the reservoir and bleed the system with a suitable grease for the obtained working conditions.

EcoPlus

.--- Menu ---.


System error 4 = Pump over current

EcoPlus




• Cause: • Control unit detected an unusual resistance in the

pump motor circuit and aborted the attempted pump cycle, possibly caused by:

• Interrupted wiring• Defective motor• Corroded contacts• Defective control unit

• Solution: • Check wiring harness between pump motor and

circuit board and restore when necessary.• Check the resistance of the motor. Replace when

necessary.• Check wiring harness contacts on corrosion. Re-

place when necessary.• Replace control unit when error persists.

EcoPlus

.--- Menu ---.


• Cause: • Lamp output detected a to high current and will be

disabled to protect the system.• Solution:

• Check power supply.• Check wiring.

EcoPlus

.--- Menu ---.


System error 8 = Pump open load

System error 16 = Lamp over load

• Cause: • Control unit encountered corrupted parameters

during power up and restored the default pro-duction settings which can be unsuitable for the current application.

• Solution: • Replace control unit.

EcoPlus

.--- Menu ---.


System error 32 = Parameter checksum error

59F214317R01Technical data

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8. TECHNICAL DATA

EcoPlus

F214317R0160 Technical data



8.1 Technical data pump unit

Maximum operating pressure: 275 bar

Operating temperature: -20 ... +70 °C

Power supply voltage: 12 or 24 Vdc

Rating pump motor (nominal at 20°C): 36 W

Rest current: 10 mA

Lamp output: Low side 1A max

Advised fusing: 15A (12 Vdc) / 10A (24Vdc)

Capacity grease reservoir: 1.7 litres

Minimum level switch: optional

Pump material: hard anodised aluminium - nylon reinforced

Delivery: Piston stroke per outlet; No.3 = 0.15cc No.4 = 0.20cc No.5 = 0.25cc

Protection class: IP67 (for lower part of pump unit)

Regulations / EMC truck : ECE-R10, rev.5, ISO 13766 (2006), ISO 14982 (2009) EN 12895 (2000), EN 13309 (2010),EN 50498 (2010) Regulation / EMC trailer : ECE-R10, rev.5, EN 50498 (2010)

Grease types: NLGI-2

290

164262

61F214317R01Technical data

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24 16 16 16 16 16 24

2525

8 4

16,5

16,5

3617

1616161616161616

8.2 Distribution blocks

Maximum operating pressure : 275bar

Operating temperature : -25 ... +70 °C

Minimum number of divider segments : 3 (excluding start and end segments)

Maximum number of divider segments : 12 (excluding start and end segments)

Material : galvanised steel

Material O-rings : NBR

Grease inlet port thread : M10 x 1 mm

Delivery per segment type 1 : 2x 0.045cc or 1x 0.090cc





Groeneveld Transport Efficiency B.V. • Stephensonweg 12 • 4207 HB Gorinchem • P.O. Box 777 • 4200 AT GorinchemThe Netherlands • T. +31 (0)183 641 400 • F. +31 (0)183 624 474 • www.groeneveld-group.com

General Manual - Groeneveld Lubrication Solutions · 2016. 12. 15. · General information...

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