Bijur Delimon SureFire II Quick Start Manual

SureFire II Lubricator

Single Phase - Quick Start Manual

Safety

General safety instructions

Electrical safety instructions

Safety instructions which promote safe operation

of the lubricator

Safety instructions which promote safe operation of the

lubricator

Conditions and actions that pose potential hazards to the user are marked by this sign.

All safety and/or warning labels affixed to the SureFire II lubricator must be maintained in a completely legible condition.

Also, any modifications made to the SureFire II Lubricator (or to any of its components) must be approved by Bijur Delimon. prior to its use, otherwise the warranty and any liability by Bijur

Delimon will be null and void.

PDI Operation

The SureFire II PDI Lubricator has a motor-driven pump that pulls lubricant in from the reservoir and delivers pressurised lubricant to the distribution network through the outlet(s) in the top plate. Pressurising the distribution network forces all of the positive displacement injectors (PDIs) in the system to fire, discharging the lubricant that was stored in each of their discharge chambers during the last pump cycle.

The pressure in the main line continues to rise activating the pressure switch until relief pressure is reached, at which stage, the relief valve opens and discharges the pressurised lubricant back into the reservoir. The pressure switch can be used to stop the motor, and momentary pressure in the main line becomes greater than the pressure at the outlet side of the gear pump.

This pressure differential actuates a quick dump valve which relieves the main line pressure back into the reservoir.

SLR Operation

The SureFire II SLR Lubricator has a motor-driven pump that pulls oil in from the reservoir and delivers pressurised oil to the distribution network through the outlet(s) in the top plate.

Pressurising the distribution network forces all of the resistance fittings in the system to discharge the oil in proportioned quantities to the friction points. The resistance fittings continue to flow and the pump builds pressure until pressure relief valve setting is reached (75 psi/5 bar). Once the motor is shut off, pressure in the distribution network returns to near 0 psi via a quick dump valve.

Installation & Commissioning

Install the SureFire II Lubricator in the horizontal position ONLY. Attach the lubricator in the desired location and to the desired equipment by means of an appropriately sized bolt through each of the (2) mounting holes in the top plate. (2L&3L=M6, 6L=M8)The lubricator should be installed in a location that is easy to access, for purposes of viewing the front panels, for ease of reservoir-filling, for ease of service and for ease of attachment to the distribution network plumbing.

Remember the SureFire II lubricator allows attachment of distribution plumbing to either (or both) sides of the top plate.

If only one side is used, be sure to plug the unused outlet with a

G1/4 BSPP plug (two plugs are included with each lubricator).

Two liquid tight fittings are supplied with the lubricator. Use the liquid tight fittings to secure the electrical wiring for the lubricator and to prevent ingress of fluids or dirt into the motor compartment. Typically one of the fittings is used to bring “power” into the motor compartment and the other fitting is used to bring “signal” into or out of the motor compartment.

All tubing, flexible hoses and fittings must be compatible with the lubricant, operating pressure and surrounding environment. In general, try to install the lubricator in the lowest position (vertically) with relation to the rest of the distribution network and do not allow the tubing to rise and fall when avoiding obstacles. This is in case air enters the distribution lines, the bubbles will tend to rise towards the end of the distribution lines and not get caught anywhere along the way. Any air bubbles trapped in the distribution network plumbing may prevent the PDI injectors from working properly.

All electrical connections are to be made by a qualified technician and all local electrical codes are to be followed. When electrical connections are being made, do so before the power leads are connected and before the power is supplied.

Consult the wiring diagram (located under the motor cover) for the correct wiring for your SureFire II lubricator.

The installation should include a means of disconnecting the power supply for servicing. Such means shall allow for switching off the power during normal operation and/ or in an emergency. Also, a residual current device is required to automatically disconnect the power supply in the event of a failure in basic insulation.

This emergency disconnecting switch shall be located in close proximity to the equipment and be within easy reach. The switch should be marked as the disconnecting device of the equipment, shall have ON/OFF positions clearly identified and should meet the requirements of IEC60947-1 or IEC60947-3.

Be sure that all plumbing distribution lines are clean, are not kinked and are free from any chips or any other impurities.

Fill the reservoir through the fill cap and/or fill cap strainer with clean lubricant specified by the Original

Equipment Manufacturer and that meets all of the lubricant specifications to the right.

Do not overfill the reservoir. Never fill past the

“MAX” level as noted on the reservoir. Overfilling could cause damage to the electrical components located under the motor cover.

Pump Priming

Filling the reservoir and turning on the lubricator is usually enough to prime the pump. However, in the case of a very thick lubricant, sometimes it’s necessary to assist priming the pump.

Upon initial startup, if no lubricant is being delivered to the pump outlet, make sure the pump is primed.

Avoid all kinds of impurities as dirt particles are the most common cause of gear pump failure. If you wish to determine whether the lubricant you plan on using is approved for use with

Bijur Lubricating Systems, you can consult the Customer

Service Department.

To prime the distribution network, plumb the entire system

(mainline tubing, manifolds, junctions, air/oil blocks, injectors, injector outlet tubing to bearing points, meter units etc.). Then, remove a plug or injector at the point furthest away from the pump. Now, run the pump until bubble-free lubricant flows from this point. Replace the plug or last injector.

Motor Duty Cycle:

100/115VAC & 200/230VAC motors: S3, 20%, 15 Min.

This means that the maximum continuous “on time” for any cycle is 3 minutes, and if the motor continuous “on time” for a cycle is X, the required minimum “off time” for that same cycle is at least 4X. Each motor has an internal high temperature cutoff switch.

24VDC motor: S1, Continuous Duty

1.

2 Litre Single Phase Standard

3 Litre Single Phase w/ Controller

Lubrication Specifications:

Standard Oil version:

20 to 1500 cSt @ operating temperature

Light Oil version:

5-40 cSt @ operating temperature

Grease version(PDI only):

NLGI grade 000 - 00 (40,000 cSt max)

BIJUR DELIMON INTERNATIONAL

TEL (+44) 01432 365000

WWW.BIJURDELIMON.COM

WWW.BDICOOLING.COM

Denco Lubrication Ltd,

Ramsden Court, Ramsden Road,

Rotherwas Industrial Estate,

Hereford, Herefordshire, HR2 6LR

71070 • R3 11/16

Component Illustration

Cable Gland

Motor Cover

Motor Assy

Pressure Switch

Pressure Gauge

System Relief

Valve

System Dump Valve

Terminal Strip

Momentary Switch

Motor On Led

Reservoir Assy

Gear Pump

Level Switch

Reservoir Assy

Oil Pressure Port

1/4 BSPP

Oil Return Port

1/4 BSPP

Filler Cap

Controller Assy

SureFire II Spare Parts

SureFire II Reservoir Size:

Part Description

24VDC Motor Kit (includes driveshaft + Coupling)

115VAC Motor Kit (includes driveshaft + Coupling)

230VAC Motor Kit (includes driveshaft + Coupling)

Reservoir Kit PLASTIC (gasket included)

Reservoir Kit METAL (gasket included)

Motor Cover Kit

Pressure Switch Kit PDI Pump

Pressure Switch Kit SLR Pump

Filler Cap Kit (with Inlet Filter Unit)

Terminal Strip Kit

Controller Kit - TIMER

Controller Kit - LITE Controller

Controller Kit - PREMIUM Controller

Membrane Switch/Label Kit for Timer/Controllers

Level Switch Kit (Standard Oil Option)

Momentary Switch Kit

Motor on LED 115VAC / 230VAC

Motor on LED 24VDC

Gear Pump Kit

Pressure Gauge (PDI)

Pressure Gauge (SLR)

Dump Valve Kit

Relief Valve Kit (PDI)

Relief Valve Kit (SLR)

Cable Gland Kit

2 Litre

Part #

71114

71064

71117

71111-2

71112-2

71113-2

3 Litre

Part #

71115

71066

71118

71119

71120

71121

71122

71123-T

71123-L

71123-P

71029

6 Litre

Part #

71111-6

71112-6

71113-6

71116

71068

71118

71124-2 71124-6

71125

71126

71127

71128

71129

71130

71131

71132

71133

71134

12 Litre

Part #

71111-12

71112-12

71113-12

N/A

71135

71118

71124-12

Maintenance and Service

The SureFire II lubricator does not require much maintenance. After initial set-up, the lubricator requires only the following maintenance: a) When filling the reservoir with oil, the lubricant must be poured through the oil-filler screen b) The oil-filler screen must be inspected after every 4 or 5 fillings and cleaned if necessary c) If filling with a fluid grease, due to the fact that

SureFire II PDI fluid grease models omit the filter screens, be sure the grease is fresh, clean, and is not higher than 40,000 cSt viscosity.

d) Do not use aggressive cleaners to clean the lubricator. Use only mild cleaners or degreasers to clean the lubricator.

In the event of having to replace a pressure gauge, appropriate pipe thread sealant applied to the male thread of the new gauge is recommended.

SureFire II Lubricator

Single Phase - Quick Start Manual

Dimensional Schematics

SureFire II 2, 3, 6 & 12 Litre (115 VAC, 230 VAC and 24 VDC Single Phase)

5

5

2 Litre

188

153

5

5

3 Litre

233

215

7

7

(184) 182.50

Measurements shown in millimeters.

9

5

5

261

225

7

332

252

176

243.50

6 Litre 12 Litre

Troubleshooting

Pre-mature wear of the gear pump and the other moving parts is usually caused by dirty or contaminated lubricant.

Failure of the PDI injectors or SLR Meter Units to deliver lubricant can be caused by an incorrect commissioning sequence, resulting in either air or dirt being trapped in the distribution network.

40

3.

9 (x4)

BIJUR DELIMON INTERNATIONAL

TEL (+44) 01432 365000

WWW.BIJURDELIMON.COM

WWW.BDICOOLING.COM

Denco Lubrication Ltd,

Ramsden Court, Ramsden Road,

Rotherwas Industrial Estate,

Hereford, Herefordshire, HR2 6LR

71070 • R3 11/16

SureFire II Lubricator

Single Phase - Quick Start Manual

24VDC Wiring Diagrams

24VDC PDI TERM BLOCK

24VDC PDI TIMER

24VDC PDI CONTROLLER

Wire Sizes - Terminal Block

Contact

All

Description

All User Terminals

(Quick Connection)

Wire Type

Solid Wire /

Stranded Wire

Size

20 - 14 AWG

(0.52 - 2.1mm

2 )

Strip Length

7.5 - 8.5 mm

Wire Sizes - Controller/Lite Controller/Timer

Contact

J1 & J2

J11 & J12

J10

Description

Power Input

(Quick Connection)

Fault Contact

(Screw Connection)

All other inputs

(Quick Connection)

Wire Type

Solid Wire /

Stranded Wire

Solid Wire /

Stranded Wire

Solid Wire /

Stranded Wire

Size

24-14 AWG

(0.2 – 2.08mm

2 )

24-16 AWG

(0.2 – 1.5mm

2 )

26-20 AWG

(0.13 – 0.52mm

2 )

Strip Length

9-10 mm

5-6 mm

9-10 mm

Note:

All wiring diagrams are located on the inside of the motor cover of Surefire II.

Motor Cover

Wire Size 20-14 AWG

(0.52-2.1mmS

8.5

7.5

Wire Strip

Length

Surefire II Technical Specifications

Output Volume – 115 VAC, 230 VAC (max.)

Single Phase:

250cc/min @ 60 Hz

210cc/min @ 50 Hz

Output Volume – 24 VDC (max.) :

250cc/min

Output Pressure (max.):

PDI: 450 psi (31 bar)

SLR: 75 psi ( 5 bar)

Motor Voltage Options:

100/115 VAC 50/60 Hz Single Phase

200/230 VAC 50/60 Hz Single Phase

24 VDC

Motor Power Requirements:

100/115 VAC Single Phase: 1.0 amps

200/230 VAC Single Phase: 0.70 amps

24VDC: 2.4 amps

Motor Duty Cycle:

100/115VAC and 200/230VAC: S3, 20%,15

Min. This means that the maximum continuous

“on time” for any cycle is 3 minutes, and if the motor continuous “on time” for a cycle is X, the required minimum “off time” for that same cycle is at least 4X. Each motor has internal high temperature cutoff switch.

24VDC motor: S1, Continuous Duty

Operating Temperature Range:

40°F through 105°F (5°C through 40°C)

IP Enclosure Rating:

IP-54

Electrical Fitting:

Liquid tight cable gland

Output Connection (x2, one each side):

G 1/4 BSPP

Return Line Connection:

G 1/4 BSPP

Reservoir Fill Screen (oil only):

40 mesh, removable

Single (main) Feed Line:

6mm O.D. minimum recommended

Reservoir Volume:

2, 3, 6 & 12 Liter

Reservoir Material:

Luran (Blue Tint) for 2, 3 and 6 litre

Steel for 2, 3, 6 and 12.0 litre

Refer to the following documents:

+ Data sheet #36410: Surefire II

4.

BIJUR DELIMON INTERNATIONAL

TEL (+44) 01432 365000

WWW.BIJURDELIMON.COM

WWW.BDICOOLING.COM

Denco Lubrication Ltd,

Ramsden Court, Ramsden Road,

Rotherwas Industrial Estate,

Hereford, Herefordshire, HR2 6LR

71070 • R3 11/16