Dynamis Maxx

of 14 PB_2011_1_GB_DYX

Product description

Electric Lubrication pump DYNAMIS Maxx

INDEX page General ................................................................................................ 2 Safety ............................................................................................ 2 – 4 Description ......................................................................................... 5 Application ......................................................................................... 5 Description of basic pumping elements .......................................... 6 A. Type of pump .............................................................................. 7 B. Lubrication system ..................................................................... 7 C. Revision ....................................................................................... 7 D. Version of pump elements ......................................................... 7 E. Reservoir size .............................................................................. 7 F. Electrical connection / Control .................................................. 8 G. Accessories ................................................................................. 8 Technical Data .................................................................................... 8 Schematic diagram of operating principles .................................... 9 Installation .......................................................................................... 9 Dimensions ....................................................................................... 10 Filling of pump ................................................................................. 11 Schematic diagram for electrical connection ............................... 12 Operation of program-controller .................................................... 12 Maintenance and Troubleshooting ................................................ 13 Example of order .............................................................................. 14


General

Before installing and operating this equipment, we highly recommend that you become thoroughly familiar with these instructions. DELIMON GmbH does not accept liability, expressed or implied, for any direct or inconsequential injuries to personnel or damage to equipment, including process interruption, arising from the misuse or misapplication of its products. Application and / or modification of product beyond its intended purpose is strictly prohibited.

DELIMON GmbH reserves the right to make modifications, changes and/or amendments to both products and to these instructions as may become necessary to assure ongoing technical clarity.

The content of this technical publication is the sole graphic and intellectual property of DELIMON GmbH and is protected by local and International Copyright Law. As such, it may not be copied, reproduced or used for any purpose other than that intended by the Company; i.e. as a guide to proper installation, maintenance and operation of its equipment by qualified personnel and their supervisors. Use of this information for any other purpose or intent requires the expressed written permission of DELIMON GmbH.

Contact Information: For assistance with product, replacement parts, service or training. DELIMON GmbH Branch Office Arminstraße 15 Am Bockwald 4 D-40277 Düsseldorf D-08344 Grünhain-Beierfeld Phone : +49 211 77 74-0 E-mail : [email protected] Fax : +49 211 77 74-210 www.bijurdelimon.com Safety

These instructions provide basic guidance which must be followed during installation, operation and maintenance. It is assumed that personnel performing required tasks are skilled in the areas of electrical and mechanical millwright trades plus all local and federal safety requirements. These instructions should be kept near the point of use and made available for reference at all times. Identification of safety warnings in the operating instructions To minimize risk to people working with this equipment, safety warnings included within these instructions must be observed. Potential safety issues are identified through use of the following general danger symbols:

Safety Sign, per DIN 4844, provides warning of potential general danger.

Safety Sign, per DIN 4844, provides warning of potential electrical danger.

ATTENTION

Caution designation utilized to signify that damage to machinery and function may result if guidance is not properly followed.

Instructions affixed directly to machines and equipment must always be observed and maintained to ensure that they are fully legible. Examples of such instructions would be:

• Rotational direction arrows for shafts and couplings. • Identification of fluid connections, direction of flow and substance contained in pipes.

Important Note: There is always increased risk of slipping or falling whenever spilled or leaking lubricants are present. In all cases, they should be properly removed and disposed of.

Safety Sign, per DIN 4844, provides warning of an increased risk of slipping and falling due to the presence of water, oil, grease or other foreign substances on pavements, floors and walkways.


Safety (continuation)

Personnel qualification and training Personnel performing work required to install, operate, maintain or inspect this equipment must be adequately trained and qualified. In this regard, determination of competency, understanding and supervision levels required for individual assignment is left to the purchaser of the equipment. However, should assistance with on-site training be desired, please contact your local DELIMON GmbH office for assistance.

Dangers in case of nonobservance of the safety instructions Failure to properly follow all safety instructions may result in hazard to personnel, the environment or to machinery and equipment. Failure to follow these instructions may also additionally void warranties and nullify claims for damages. Examples of such instances follow: • Failure of machinery or operating systems to function properly • Failure to observe proper methods of maintenance and repair • Unnecessary creation of hazards to personnel by means of electrical shock, mechanical injury or

exposure to potentially hazardous chemicals • Unnecessary creation of environmental hazards through chemical leaks

Safety conscious working All Safety Instructions resulting from National, Local or User mandated regulations, as well as those contained within this instruction, must be observed at all times.

Safety instructions for the user/operator • Users should always take care that only authorized and skilled personnel are allowed to perform

installation, maintenance and inspection work. • Installation, maintenance and inspection of lubrication systems should only be performed while

machinery and equipment being serviced is in “Shut-Down Mode”. • Protective covers and guards, provided to ensure that contact with moving parts is eliminated during

machine operation, (e.g. couplings, pulleys, gears, etc.), must be replaced following maintenance and repair.

• Use “Common Sense”! When hot or cold machine parts can lead to potential dangers, those parts must be handled in such manner so as to avoid human touch; i.e. shielding is required.

• Leaks from shaft seals, reservoirs, piping or fittings should be repaired so as to not cause potentially hazardous materials from escaping to the work area. In instances where such leaks have occurred, all local and National rules and regulations for their recovery and disposition must be followed.

• All potential hazards resulting from exposure to electrical sources must be eliminated. Please refer to VDE and local power company rules and regulations for guidance.

• Before restarting system and equipment, refer to instruction in Section 7; Start-Up Procedure.

Safety instructions for maintenance, inspection and installation work Before installing or servicing lubrication equipment and machinery, management should insure that only persons who are fully trained, skilled and authorized to perform such work are assigned to such tasks. Major installation or modification work should only be performed during shut-downs. It is also imperative that shut-down procedures recommended by equipment manufacturers be followed. Pumps, lubricators and distribution systems which deliver potentially hazardous materials to the environment must be thoroughly cleaned. All safety devices and protective equipment, disabled or removed during cleaning, must be immediately reinstalled and reactivated prior to machine use.

Safety Sign, per DIN 4844, Use Safety Glasses or Goggles. Advice: Whenever working with compressed air, wear safety glasses

Safety Sign, per DIN 4844, Use Breathing Mask. Advice: Observe EC-Safety Data Sheet for materials of consumption and additives used and use personal protective equipment.


Safety (continuation)

Unauthorized conversion and manufacture of spare parts The modification and/or manufacturing of parts for use as spare or replacement parts in DELIMON

lubrication equipment, without the written consent and approval of DELIMON Engineering, is strictly prohibited. Any such modification and/or manufacture of component parts shall immediately render any and all warranties as null and void.

Unacceptable modes of operation The operational integrity and reliability of all equipment supplied is warranted only when said equipment is utilized in strict accordance with parameters established in Section 1; Introduction. Maximum operating parameters outlined in Engineering Data Sheets must never be exceeded.

Guidelines & standards 1., 2. and 3. guideline (see data sheet: R&N_2009_1_GB) Notes on environmental protection and waste disposal During proper operation, various component parts of lubricating systems are subject to special requirements as set forth by Environmental Legislation. General requirements for handling lubricants are specified in their respective safety data sheets. Used lubricants are hazardous forms of waste and therefore require special handling and supervision with regard to § 41 paragraph 1, sentence 1 and paragraph 3 no. 1 of KrW-/AbfG (Closed-Loop Waste Management Act). Used oils must be handled in compliance with AltölV (Waste Oil Ordinance). Any devices or components which become contaminated with lubricant must be disposed of by a certified waste management company. Additionally, records indicating proper conformance to waste management practice and law must be filed according to NachwV (Ordinance on Waste Recovery and Disposal Records).


GENERAL PRODUCT CHARACTERISTICS

• Pump for single-line, multi-line, progressive, air-oil and spray systems • Lubricant: oil, liquid grease and grease up to NLGI class No. 2 • Discharge pressure via pressure relief valve 160 or 300 bar • Integrated controller (optional) • 1 - 3 pump elements/outlets. 12 outlets at maximum with assembled progressive divider (optional) DESCRIPTION

The Model DYNAMIS Maxx is a 24VDC electrically driven grease pump which can be provided with dust and rain proof motors. If required, the pump can also be equipped with a 115/230 V AC converter. The pump is dust and water proof according to protection class IP67. The outer diameter of the pump reservoir is 220 mm, resulting in a slightly larger footprint than other pumps in its class. The reservoir is equipped with a steering blade assuring that lubricant is continuously directed towards the pump inlet. To enhance operation, the reservoir is equipped with a spring loaded follower plate. The pump’s lower section features a convex design to minimize residual lubricant levels. The DYNAMIS Maxx pump can be conveniently equipped with the compact “pCo” controller. To facilitate monitoring of the reservoir lubricant level, the pump can be equipped with an optional proximity switch. Electrical contacts can also be provided for remote reservoir level indication. The DYNAMIS Maxx pump is available with 4 liter, 8 liter, 12 liter, 15 liter and 20 liter reservoirs. Reservoirs are constructed utilizing clear engineering polymers. Outlet pressures of 300 bar are achievable. The DYNAMIS Maxx pump can be configured as: - a multi-line system with up to three seperate lubrication lines, each protected by a pressure relief valve - a progressive system with direct assembled progressive divider - a single-line PDI system with integrated relief valve, residual pressure valve and pressure switch mounted at the pump APPLICATION

The DYNAMIS Maxx pump is designed to power centralized lubrication systems in wind turbine, engineering reliability, test and inspection machines, moving mechanisms and machine tool applications.


Grease reservoir

G ¼ Outlet (Safety valve)


Grease filling inlet

Spannungsversorgung

Signal output

DESCRIPTION OF BASIC PUMPING ELEMENTS

+ Type with follower piston + Type with stirring wing

Grease filling inlet



Circuit interface

Signal output

Grease reservoir

M20x1,5 Plug screw

Circuit interface


A. PUMP TYPE Code DYX B. KIND OF SYSTEM Code Version for multi-line system ML Version for single-line system EL Version with progressive distributor (selection in seperate sheet) Version for spraying lubrication with free outlet (outlets) SP Version for spraying lubrication with progressive distributor (selection in seperate sheet) Version for air-oil system OL C. REVISION Code Status A A D. VERSION OF PUMP ELEMENTS Code 1. Pump element without pump element A with pump element, without pressure relief valve B with pump element, with pressure relief valve 160 bar C with pump element, with pressure relief valve 300 bar D

2. Pump element without pump element A with pump element, without pressure relief valve B with pump element, with pressure relief valve 160 bar C with pump element, with pressure relief valve 300 bar D

3. Pump element without pump element A with pump element, without pressure relief valve B with pump element, with pressure relief valve 160 bar C with pump element, with pressure relief valve 300 bar D

connected pump elements without 0 Pump elements 1 and 2 at 1 connected, 3 separate 1 Pump elements 1, 2 and 3 at 1 connected 2 E. RESERVOIR SIZE Code 4 liter with follower plate, without level control, with filling junction A 8 liter with follower plate, without level control, with filling junction B 12 liter with follower plate, without level control, with filling junction C 15 liter with follower plate, without level control, with filling junction D 20 liter with follower plate, without level control, with filling junction E 4 liter with follower plate, with level control Leer, with filling junction F 8 liter with follower plate, with level control Leer, with filling junction G 12 liter with follower plate, with level control Leer, with filling junction H 15 liter with follower plate, with level control Leer, with filling junction I 20 liter with follower plate, with level control Leer, with filling junction J 4 liter without follower plate, without level control, with filling junction K 8 liter without follower plate, without level control, with filling junction L 12 liter without follower plate, without level control, with filling junction M 15 liter without follower plate, without level control, with filling junction N 20 liter without follower plate, without level control, with filling junction O


F. ELECTRICAL CONNECTION / CONTROL Code Internal control 24 V DC 1 x plug M 12x1, 5-pole 01 1 x plug M 12x1, 5-pole + 1 x plug M 12x1, 8-pole 02 1 x plug M 12x1, 5-pole + 1 x cable duct M 20x1,5 03 1 x plug M 12x1, 5-pole + 1 x plug M12x1, 8-pole + 1 x cable duct M 20x1.5 04 Internal control 230 V AC 1 x plug DIN 43650, 3-pole 05 1 x plug DIN 43650, 3-pole + 1 x plug M 12x1, 8-pole 06 1 x plug DIN 43650, 3-pole + 1 x cable duct M 20x1,5 07 1 x plug DIN 43650, 3-pole + 1 x plug M12x1, 8-pole + 1 x cable duct M 20x1.5 08

Advice: Plug connector M 12x1, 5-pole - for each DC pump type to supply the pump Plug DIN 43650, 3- pole - for each AC Pump type to supply the pump Plug connector M 12 x 1, 8-pole - for status signal Cable duct through M20x1,5 for connection of sensors/pressure switches within the pump

without control 24 V DC 1 x plug M 12x1, 5-pole 11 1 x plug M 12x1, 5-pole + 1 x plug M 12x1, 4-pole 12 1 x plug M 12x1, 5-pole + 1 x plug M 12x1, 4-pole + 1 x cable duct M 20x1.5 13 1 x plug M 12x1, 5-pole + 1 x plug M 12x1, 8-pole + 1 x cable duct M 20x1.5 14 without control 230 V AC 1 x plug DIN 43650, 3-pole 15 1 x plug DIN 43650, 3-pole + 1 x plug M 12x1, 4-pole 16 1 x plug DIN 43650, 3-pole + 1 x plug M 12x1, 4-pole + 1 x cable duct M 20x1.5 17 1 x plug DIN 43650, 3-pole + 1 x plug M 12x1, 8-pole + 1 x cable duct M 20x1.5 18

Advice: Plug connector M 12x1, 5-pole - for each DC pump type to connect the gear motor Plug DIN 43650, 3-pole - for each AC pump type to connect the gear motor Plug connector M 12x1, 4-pole - for up to 2 status signals Plug connector M 12x1, 8-pole - for up to 5 status signals Cable feed through M 20x1.5 for connection of sensor/pressure switches within the pump G. ACCESSORIES Code without 00 TECHNICAL DATA

Rated pressure : ............................................................................................................................... 300 bar Motor voltage : ..................................................................................................... 24 V DC or 115/230 V AC Motor power : ........................................................................................................................................ 50 W Outlet screw : ........................................................................................................................................ G 1/4 Rated single-piston delivery rate : .............................................................................................. 4,0 cm³/min Operating temperature : ..................................................................................................... - 30°C to + 75°C Acceptable lubricants : ...................................................................................................... NLGI 000 class 2 ...................................................... (if operated at low temperature, select low temperature lubricant) Available reservoir capacities : ................................................................................. 4 l, 8 l, 12 l, 15 l or 20 l Dischatge element output port (wahlweise): ........................................................... Schnellverbinder Rc1/4 Schutzart : ............................................................................................................................................. IP67 Notes: 1. Lubricants should be selected according to specific operating temperatures.

Contact Bijur Delimon should you require additional assistance.

2. Electrical specification Number of connections : .......................................................................................................... 3 + PE

Specification of power cable : .......................................................................................... AWG20 -14 Diameter of power cable : ................................................................................................. 6 – 9,5 mm Protection system : ...................................................................................................................... IP67


SCHEMATIC DIAGRAM OF OPERATING PRINCIPLES

follower piston stirring wing

Operating principles of DYNAMIS Maxx pump A needle bearing supported cam, driven by a direct current motor, results in the piston generating a suction and compression stroke. An optional safety relief valve is positioned downstream from the pump outlet. As such, maximum outlet pressure can be restricted up to 300 bar. When the pump is utilized in multi-line systems, the outlet pressure for each outlet can be controlled separately. When used in progressive or single-line PDI systems, relief pressure will be determined by choosing appropriate pressure relief valves. INSTALLATION

Position of mounting holes

The pump is mounted utilizing four screws ISO 4762 M10x40-8.8.

Notes: The pumping unit should always be installed in an appropriate location; generally where it will not be disturbed and away from damaging influences. Refer to the drawing for information on proper spacing of mounting holes. The mounting surface should be even / flat and all mounting connections should be secure and reliable. Open space should always be provided on both sides of the unit to facilitate future periodic inspections.


DIMENSIONS (mm)

+ follower piston

Grease tank capacity 4 liter 8 liter 12 liter 15 liter 20 liter

L (mm) 390 490 590 690 820

Inspection before pump start-up Fill the pump utilizing the grease fill fitting provided, making sure to use a clean grease lubricant having an appropriate viscosity for the environment and application. Never remove the top cover to fill. Connect the electrical connection cable and the signal cable according the circuit diagram. Connect power cables and alarm signal wires according to specified system requirements. Note that the power voltage must conform to the rated voltage of the electric motor. Please pay particular attention to the positive and negative poles of the power supply. The power supply must be properly connected to the pump unit and all wiring must be secured as may be required by national and local codes. Check so see if there is any evidence of leakage at the fittings located between the lubricating pump and the distribution system. Correct if necessary. Check so see if there is any leakage at all connectors and joints throughout the system. Make sure all connections are reliable and securely fastened.

Outlets

Fixing bores

Filling junction


FILLING OF LUBRICANT

Fill the reservoir with grease through the fitting provided on the pump body. Use of an electric or air driven filling pump is recommended. Be careful to not overpressurize or overfill the reservoir as damage to the unit may result. Never remove the top plate for filling. Please contact us should further questions arise. Level confirmation Visual Inspection: Lubricant level can be conveniently monitored by visually inspecting the reservoir. Periodic inspections should be performed ensure proper lubrication as well as for safety purposes. Whenever lubricant falls below the “min” line (minimum), grease should immediately be fed into the tank to replenish the supply. Failure to maintain grease above the “min” level enables air to enter the unit, which in turn, leads to system failure. Automatic inspection: DYNAMIS Maxx lubricators can be equipped with an automatic oil level switch for monitoring inspection. If the grease level is lower than minimum, the lubricator will stop operating automatically in order to protect the system.

Filling junction


SCHEMATIC DIAGRAM OF ELECTRICAL CONNECTION

+ without level signal output

+ with level signal output

OPERATION OF PROGRAM-CONTROLLER

Detailed information relating to all controller activated functions can be found the operating manual for “pCo” Dynamis“.

Power input connector 1-red 2-blue

Signal output connector 1-brown 2-blue 3-yellow -black

Power input connector 1-brown 2-blue


MAINTENANCE

• During assembly, only clean piping should be used. • Always use fresh, clean grease. • In order to prevent air entrapment, always use the special filling connection whenever adding

grease. • Pipe tape and floss may be used for threaded connections. • The system should be checked periodically for damage. • To ensure maximum pump life, programming should only activate / operate the pump for 5 minutes

maximum per working cycle. Dwell (off) times should always be more than 2 minutes. Note: BIJUR DELIMON shall not be held responsible for any damage to products arising from the improper operation of the units. Please contact BDI for additional information. TROUBLESHOOTING

Symptom Possible cause Remedy No grease delivery at outlets

Motor does not rotate Check power supply and motor Air entrapment exists on the bottom of the reservoir

Care should always be taken to prevent air from entering reservoirs during filling

Pressure fails to build

Leakage at piping connection Check for and remove leakage problems Pumping elements are damaged Contact us Electromagnetic valve core does not close

Check coils or windings

Electrical motor stop pump fails to upload

Lubrication points cannot adjust lubricant (only in case of missing safety valves)

Remove blockage at the lubrication point.


EXAMPLE OF ORDERING

Code DYX ML A C C C 0 A 02 00

Pump type DYNAMIS Maxx Code: DYX

Kind of system Version for multi-line system Code: ML

Revision Status A Code: A

Version of pump elements with pump element, with pressure relief valve 160 bar

Code: C


Code: C


Code: C

Version of pump elements connected pump elements, without

Code: 0

Reservoir size 4 liter with follower plate, without level control, with filling junction

Code: A

Electrical connection / control internal control 24 V DC 1 x plug M12x1, 5-pole + 1 x plug M12x1, 8-pole

Code: 02

Accessories without Code: 00

Dynamis Maxx

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Transcript of Dynamis Maxx