Groeneveld TWIN General Manual
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Groeneveld TWIN General Manual

Automatic greasing system
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General Manual
TWIN
Automatic TWIN Greasing System
EG1701
your efficiency is our challenge

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  • Page 1 General Manual TWIN Automatic TWIN Greasing System EG1701 your efficiency is our challenge...
  • Page 2 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.

  • Page 3: Table Of Contents

    The operating mode push-button - - - - - - - - - - - - - - - - - - - - 15 2.3.7. The Twin display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15 2.4.
  • Page 4 TWIN General Manual Maintenance instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39 5.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40 5.2.

  • Page 5: Preface

    TWIN General Manual your efficiency is our challenge Preface EG1701...
  • Page 6 TWIN General Manual This system manual is a description of the Twin Automatic Greasing System. The intention is to provide clients with an insight into how the system works, what the possibilities are and, briefly, maintenance aspects. Furthermore, you will find the technical data of the various parts of the greasing system in this manual.

  • Page 7: Introduction

    TWIN General Manual your efficiency is our challenge Introduction EG1701...

  • Page 8: Introduction

    TWIN General Manual Introduction This chapter is a short presentation of Groeneveld Transport Efficiency and its products. The chapter ends with some general remarks about the Twin greasing systems. GROENEVELD Transport Efficiency B.V. Investing in operational safety. With this thought in mind, Groeneveld was founded in 1971.

  • Page 9: Groeneveld Greasing Systems

    Twin Automatic Greasing Systems With a Twin Groeneveld automatic greasing system, all greasing points of a vehicle or machine are automatically greased at the correct time with the correct dose. Moreover, optimum grease distribution over the whole greasing surface is achieved, because the greasing takes place while the machinery or vehicle is in operation.
  • Page 10 TWIN General Manual Notes Introduction EG1701...

  • Page 11: Description Of The System

    TWIN General Manual your efficiency is our challenge Description of the system EG1701...

  • Page 12: Introduction

    * When an automatic greasing system is installed on an apparatus controlled by a PLC (Programmable Logic Controller), the PLC may also control the greasing sys- tem. In this case, the Twin pump unit will be delivered without a control unit. Description of the system...

  • Page 13: Description Of The Parts

    TWIN General Manual Cycle A Cycle B figure 2.1 Overview of the Twin automatic greasing system Description of the parts 2.3.1 Grease pump The relief valve A relief valve is mounted in the grease line between the plunger-pump and the diverter-valves.

  • Page 14: Control Unit

    2.3.3 Distribution blocks and metering units Various types of metering units with the Twin greasing system are available, each with a different grease output. Each greasing point can receive the correct dose of grease per greasing cycle by a careful choice of the type of metering unit.

  • Page 15: Grease Pressure Switch

    2.3.7 The Twin display In addition to an operating mode push-button with integrated signal lamp, a Twin display with extra functions is available. The Twin display continuously indicates the adjusted operating mode with green LEDs. A yellow LED lights when the minimum grease level is reached and a red LED lights when a malfunction occurs.

  • Page 16: The Greasing Cycle

    TWIN General Manual The greasing cycle Every greasing cycle consists of four phases. The greasing cycles are carried out alternately by the grease lines A and B (see figure 2.1 and figure 2.4). The 5/2 valve, which is integrated in the pump housing, determines which primary grease line is connected to the pump and which is connected to the grease reservoir.

  • Page 17: Greasing Cycle B

    TWIN General Manual The pressure decrease phase The pressure decrease phase follows the re-grease phase. In this phase, the pressure in the primary grease line is decreased through the 5/2 valve. To accomplish this, the control unit energizes the 5/2 valve, so the grease pressure in primary grease line A is decreased and the grease flows back to the reservoir.
  • Page 18 TWIN General Manual Notes Description of the system EG1701...

  • Page 19: Principle Of Operation

    TWIN General Manual your efficiency is our challenge Principle of operation EG1701...

  • Page 20: Introduction

    The pump unit, metering units, grease pressure valve, control unit, signal lamp and display are discussed. Pump unit The Twin pump unit consists of various parts. These parts are shown in figure 3.1. 1. grease follower piston 11. electro-motor 2.
  • Page 21 TWIN General Manual The heart of the pump is an electrical-driven plunger-pump. This pump consists of three radially-placed fixed cylinders and plungers (5, see figure 3.1). The electro- motor drives the axle through the mechanical drive. A cam (4) is fixed on the axle that moves the three plungers to and fro, so the grease is pumped to the distribution blocks through the primary grease line.

  • Page 22: Metering Units

    TWIN General Manual The 5/2 magnetic valve Primary grease line A (port A) Primary grease line B (port B) From pump Return line A to grease reservoir Return line B to grease reservoir figure 3.2 5/2 magnetic valve When the 5/2 magnetic valve is at stationary (not energized by the control unit, see figure 3.2), greasing will take place through primary grease line A and the pressure...
  • Page 23 TWIN General Manual Phase 1 In this phase, the metering unit has not yet filled with grease (see figure 3.3). figure 3.3 Principle of operation of the metering unit - first phase While in operation (system completely filled with grease) phases 3 and 4 will take place alternately.
  • Page 24 TWIN General Manual Phase 3 Grease is pumped into channel (6) of the metering unit (pumping phase B) through primary channel B (see figure 3.5). Because of the grease pressure, plunger (3) is pushed back leftwards, passed channel (8). The grease fills chamber (7) and pushes plunger (4) back to the left.

  • Page 25: Grease Pressure Switch

    TWIN General Manual Grease pressure switch The principle of operation of the grease pressure switch is explained in three phases. Phase 1 During this phase both channels A and B are not under pressure (see figure 3.7). There is also no pressure in chamber (1). Spring (10) pushes switch plunger (2) to the left.
  • Page 26 TWIN General Manual Phase 3 (pumping phase B) During pumping phase B grease is pressed into channel B (see figure 3.9). While the grease pressure is built up, chamber (11) fills with grease (through channel 12). The grease pressure pushes piston (6) to the left. Because of that the channel (8) is opened, causing the grease to flow to chamber (1) through channel (7) and channel (9).

  • Page 27: Control Unit

    TWIN General Manual Control unit 3.5.1 Introduction The greasing system is controlled by an electronic control unit. The sensors that check specific parts or the complete greasing system for malfunctions are connected to the control unit. The control unit controls the greasing system by: •...

  • Page 28: The Length Of The Greasing Cycles

    TWIN General Manual 3.5.2 The length of the greasing cycles The meaning of the various phases of the greasing cycle is described in paragraph 2.4. (further see figure 3.10.) The duration of a greasing cycle (adjustment range: 0 ... 1440 minutes) is defined as the period that expires between two successive pumping phases: beginning from the start of one pumping phase and ending at the start of the next pumping phase.

  • Page 29: Length Of The Re-Grease And Pressure Decrease Phases

    TWIN General Manual 3.5.4 Length of the re-grease and pressure decrease phases The duration of the re-grease phase is equal to the length of the pressure decrease phase. The pressure decrease phase is proportional to the length of the pumping phase.

  • Page 30: The Log

    TWIN General Manual 3.5.7 The log The control unit distinguishes 11 different malfunction reports that are recorded in three groups. Every group has eleven different counters per malfunction report. The three malfunction groups are: Counters for the total number of times a certain has occurred since the instal- lation of the greasing system.

  • Page 31: Signal Lamp

    TWIN General Manual Signal lamp The signal lamp (see figure 3.11) is mounted in the field of vision of the driver and out of direct sunlight, because of the visibility of the signals. Possibly this button can be combined with the operating push-button. The lamp...

  • Page 32: Twin Display

    TWIN General Manual Twin display A Twin display is also deliverable instead of the operating mode push-button with integrated signal lamp. this display green LEDs continuously indicate the adjusted operating mode. In addition, this display is equipped with a yellow warning LED (minimum grease level reached), a red LED (system malfunction) and a push-button to adjust the desired operating mode.

  • Page 33: Operating Instructions

    TWIN General Manual your efficiency is our challenge Operating instructions EG1701...

  • Page 34: Introduction

    Twin display If, instead of a separate operating mode push-button, a Twin display is used, the adjusted operating mode is indicated continuously by a green LED. By pushing the push-button on the display, the operating mode can be switched at every desired moment.

  • Page 35: The Test Push-Button

    TWIN General Manual The test push-button 4.4.1 Introduction To test the greasing system two different test cycles can be carried out with the test push-button on the grease pump unit (see figure 4.1): the single-test cycle (through the A- or B-grease line);...

  • Page 36: The Continuous-Test Cycle

    The GINA (Groeneveld tester for INstallation and Analysis) is an apparatus with which the digital control unit of the Twin greasing system can be read and adjusted. The GINA is not supplied with the system as standard. A description of how to connect and switch on the GINA follows.

  • Page 37: Operating Panel

    TWIN General Manual 4.5.2 Operating panel The GINA consists of a display with 4 lines and an operating panel. (see figure 4.2). 2 2 2 5 5 5 figure 4.2 Operating panel of the GINA The operating panel contains the following keys:...

  • Page 38: Connecting And Switching On The Gina

    4.5.3 Connecting and switching on the GINA Connect the GINA to the Twin pump unit with use of the connecting cables. Switch on the power supply of the control unit (contact switch of the vehicle). Switch on the GINA after 8 s.

  • Page 39: Maintenance Instructions

    TWIN General Manual your efficiency is our challenge Maintenance instructions EG1701...

  • Page 40: Introduction

    TWIN General Manual Introduction In this chapter all important aspects of maintenance of the Twin automatic greasing system are discussed. These aspects are the overhaul (periodic check), bleeding of the system, refilling the grease reservoir and finding the malfunctions. Overhaul The overhaul of the greasing system requires little time and effort and can be combined with the normal service of the vehicle (e.g., during the oil change).

  • Page 41: Re-Filling The Grease Reservoir

    Use of the correct grease WARNING: It is of the utmost importance that the correct grease is used in the Twin greasing system. Please consult the maintenance manuals of the vehicle, as they are drawn up by the manufacturer of the vehicle. Please consult the grease provider or Groe- neveld when a different grease is to be used.

  • Page 42: Finding Malfunctions

    5.5.1 General The Twin greasing system is equipped as standard with an electronic control unit with a database. All relevant data concerning the functioning of the greasing system are stored in that database. This data can be read with a GINA (or a PC or laptop).

  • Page 43: Malfunction Finding Table

    To make it easier to find malfunctions (when no GINA is available), refer to the malfunction finding table. In this table, probable causes of malfunctions and their solutions are listed. Because malfunction reports through the Twin display varies a little from the reports through the signal lamp, a separate table is inserted.
  • Page 44 TWIN General Manual Malfunction Cause Solution 3. Signal lamp lights The grease pressure switch continuously for 2 did not switch. minutes at the end of Probable causes: every pumping phase. a. The primary grease line a. Replace or repair the line leaks.
  • Page 45 TWIN General Manual Malfunction Cause Solution 4. Signal lamp lights a. A connected series of 11 a. Push the test button on continuously when identical malfunction the pump for at least 1 s to the contact switch is reports or 11 malfunction reset the report.
  • Page 46 TWIN General Manual Malfunction reports of the Twin display Malfunction Cause Solution 5. Display still gives a. No supply voltage on the a. Check the fuses and/or no signal after 1 display. feeder connection (grey minute. wire no. 1), Replace or repair it if necessary.
  • Page 47 TWIN General Manual General Malfunction Cause Solution 9. All grease points a. The adjusted greasing a. Adjust a shorter greasing contain no grease interval is too long for the time interval with the push- and no malfunction relevant application. button (if present) or with reports have been the GINA.
  • Page 48 TWIN General Manual Malfunction Cause Solution 13. The signal lamp A single-test cycle is carried The signal lamp goes out flashes (2 s on - 2 s out. after the test cycle has off) during one ended or after turning off complete greasing the contact switch.

  • Page 49: Malfunction Finding Procedures

    TWIN General Manual 5.5.4 Malfunction finding procedures A number of procedures to determine the correct cause of a certain malfunction are described below. Procedure to check the correct working of the grease pressure switch and cable Disconnect the 2-pole connector from the pressure switch.
  • Page 50 TWIN General Manual Procedure to check the working of the pump and the 5/2-magnetic valve Disconnect both grease lines (channel A and B) from the pump unit. ATTENTION: Some pressure can still be present in the channels. Connect a pressure gauge to each channel of the pump unit. Use pressure gauges that are suitable for a grease pressure of 250 bar.
  • Page 51 TWIN General Manual Procedure when an internal system leak is suspected Disconnect channel B of the pump unit. ATTENTION: Some grease pressure can still be present in the channel. Press the test push-button for about 4 s to start a test cycle.
  • Page 52 TWIN General Manual Notes Maintenance instructions EG1701...

  • Page 53: Explanatory Word List

    TWIN General Manual your efficiency is our challenge Explanatory word list EG1701...
  • Page 54 Pause phase The period in which the greasing system is at rest. For a Twin greasing system this is the period that follows the pressure decrease phase. Pressure decrease The period in which the grease pressure decreases.

  • Page 55: Technical Data

    TWIN General Manual APPENDIX A your efficiency is our challenge Technical data EG1701...
  • Page 56 TWIN General Manual Twin pump units Pump numbers with an F are filled with Greenlube EP-2 grease. part number 63601 63701 63801 70001* F112589 F112126 F112942 Supply voltage (Vdc) Volume reservoir (litre) Output (cm / min.) Maximum grease pressure (bar)
  • Page 57 Signal lamp Absorbed power: 3 W Grease pressure switch The grease pressure switch is mounted with use of a diverter valve on a Twin distribution block. This can be a brass (part number 66601) or stainless steel (part number 91401) valve.
  • Page 58 TWIN General Manual Notes Technical data EG1701...
  • Page 59 TWIN General Manual Numeric 5/2 valve - - - - - - - - - - 16, 21, 22 GINA - - - - - - - - - - - - 14, 36, 54 connecting - - - - - - - - - - - 38...
  • Page 60 - - - - - - - -13, 35 normal duty - - - - - - - - - - - 34 TWIN - - - - - - - - - - - - - - - - - 36 operating mode push-button - - 15...
  • Page 61 Tel.: +49 2841 793520 Tel.: +34 93 8171822 Fax: +49 2841 7935222 Fax: +34 93 8172061 Groeneveld France Groeneveld Transport Efficiency U.K. Ltd. 53, rue Antoine Condorcet The Greentec Centre 38090 Vaulx Milieu, FRANCE Gelders Hall Road, Shepshed Tel.: +33 4 74999333...
  • Page 62 Groeneveld Transport Efficiency B.V., Stephensonweg 12, 4207 HB Gorinchem, Postbus 777, 4200 AT Gorinchem, the Netherlands. Tel. +31 183 64 14 00, Fax +31 183 62 34 05, http:// www.groeneveld-groep.com...

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