Bijur Delimon SureFire II Instruction manual

1
DENCO LUBRICATION LTD
([phone] TELEFON
([phone] FAX
WWW.BIJURDELIMON.COM
WWW.BDICOOLING.COM
Ramsden Court, Ramsden Rd,
Rotherwas Industrial Estate,
Hereford, HR2 6LR
71070 • R3 1/17_GB
SureFire II Lubricator
Quick Start Manual
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 pressurized oil to
the distribution network through the outlet(s) in the top
plate. Pressurizing 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 and 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 getting 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
2 Litre Single Phase Standard
3 Litre Single Phase w/ Controller
SAFETY
General safety instructions
Electrical safety instructions
Safety instructions which promote safe
operation of the lubricator
Electrical connections made to Earth ground are
identified by this symbol
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.
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 provide
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 should be located in
close proximity to the equipment and within easy reach. The
switch should be marked as the disconnecting device of the
equipment and have ON/OFF positions clearly identified. It
should also 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 start-up, 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.
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)
Motor Duty Cycle:
100/115VAC and 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 cut-off switch.
24 VDC motor: S1, Continuous Duty

2BIJUR DELIMON INTERNATIONAL QUICK START SUREFIRE II 71070 • R3 1/17_GB
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.
Reservoir Assy
Pressure Gauge
Oil Pressure Port
1/4 BSPP
Oil Return Port
1/4 BSPP
Pressure Switch
Motor Assy
Terminal Strip
Cable Gland
Motor Cover
Filler Cap
Gear Pump
Level Switch
Momentary Switch
Motor On Led
System Relief Valve
System Dump Valve
Controller Assy
Component Illustration
SureFire II Spare Parts
SureFire II Reservoir Size: 2 Liter 3 Liter 6 Liter 12 Liter
Part Description Part # Part # Part # Part #
24VDC Motor Kit (includes driveshaft + Coupling) 71111-2 71111-6 71111-12
115VAC Motor Kit (includes driveshaft + Coupling) 71112-2 71112-6 71112-12
230VAC Motor Kit (includes driveshaft + Coupling) 71113-2 71113-6 71113-12
Reservoir Kit PLASTIC (gasket included) 71114 71115 71116 N/A
Reservoir Kit METAL (gasket included) 71064 71066 71068 71135
Motor Cover Kit 71117 71118 71118 71118
Pressure Switch Kit PDI Pump 71119
Pressure Switch Kit SLR Pump 71120
Filler Cap Kit (with Inlet Filter Unit) 71121
Terminal Strip Kit 71122
Controller Kit - TIMER 71123-T
Controller Kit - LITE Controller 71123-L
Controller Kit - PREMIUM Controller 71123-P
Membrane Switch/Label Kit for Timer/Controllers 71029
Level Switch Kit (Standard Oil Option) 71124-2 71124-6 71124-12
Momentary Switch Kit 71125
Motor on LED 115VAC / 230VAC 71126
Motor on LED 24VDC 71127
Gear Pump Kit 71128
Pressure Gauge (PDI) 71129
Pressure Gauge (SLR) 71130
Dump Valve Kit 71131
Relief Valve Kit (PDI) 71132
Relief Valve Kit (SLR) 71133
Cable Gland Kit 71134

3QUICK START SUREFIRE II 71070 • R3 1/17_GB BIJUR DELIMON INTERNATIONAL
Measurements shown in millimeters.
Dimensional Schematics
SureFire II 2, 3, 6 & 12 Litre (115 VAC, 230 VAC and 24 VDC Single Phase)
176
40
9(x4)
252
332
12 Litre
5
261
225
243.50
5
233
5
182.50
215
5
1535
5 188
184
Ø 7 Ø 7
Ø 9
6 Litre
3 Litre2 Litre
Troubleshooting
Premature 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.

4
DENCO LUBRICATION LTD
([phone] TELEFON
([phone] FAX
WWW.BIJURDELIMON.COM
WWW.BDICOOLING.COM
Ramsden Court, Ramsden Rd,
Rotherwas Industrial Estate,
Hereford, HR2 6LR
71070 • R3 1/17_GB
24 V DC Wiring Diagrams
24 VDC PDI TERMINAL BLOCK
24 VDC PDI TIMER
24 VDC PDI CONTROLLER
2
10
9
10
9
G/Y
--
--
--
--
--
P/N 71043-24 R0
OR
OR
BK
BK
YE
YE
BK
BK
BK
RD
MOM. SW
MOM. SW
PRESS. SW
PRESS. SW
LEVEL SW
LEVEL SW
0V DC
M
24V DC
E
13
12
11
10
9
8
7
6
5
4
3
1
E
P/N 71043-24T R0
J10
J2 J1
J11 J12
123 1
2
3
18 1716 15 14 131211 10 987654321
4321 87654321
24V
M
COM
N/O N/C
level
switch
K1 fault
contact
Ɵmer
YE
YE
BK
RD
0V
pressure
switch
(wire direct)
F1
RD
P/N 71043-24C-A R0
J10
J2 J1
J11
J12
123
1
2
3
18 1716 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
4321 87654321
M
Level
full
controller
pressure
BU
BK
Cycle switch *
OR
( Dry Contact / NPN / PNP )
M12X1
Connector
12
34
5
M12X1
CONN'R
-X1
-X2
-X2,PIN 4
-X2,PIN 5
K2
K1
-X2,PIN 1 BN
-X2,PIN 2 WH
-X2,PIN 3 BU
BK
GY
BN
LOW
WARN
Air
switch *
switch
switch
Oil
* External KƉƟŽŶƐ
sensor *
Oil
streak
BU
BK
WH
BN
Event switch *
(Dry Contact/NPN/PNP)
12V
0V
S
1
5
4
2
3
BN -X1,PIN 1
24V
0V
E
BU -X1,PIN 3
G/Y -X1,PIN 5
F1
12V
BK
BK
Lube
+- s
BK
pressure
Pin No Description
1K1-Com
2 K1 - N/C
3 K1 - N/O
4 K2 - Com
5K2-N/C
Note:
All wiring diagrams are located on the
inside of the motor cover of Surefire II.
Motor Cover
Refer to the following documents:
+Data sheet #36410: Surefire II
Surefire II Technical Specifications:
Output Volume – 115 VAC, 230 VAC (max.)
Single Phase:
250cc/min at 60 Hz
210cc/min at 50 Hz
Output Volume – 24 VDC (max.):
250cc/min
Output Pressure (max.):
PDI: 31 bar
SLR: 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
24 VDC: 2.4 amps
Motor Duty Cycle:
100/115 VAC and 200/230 VAC: 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 cut-off switch.
24 VDC motor: S1, Continuous Duty
Operating Temperature Range:
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 litre
Reservoir Material:
Luran (Blue Tint) for 2, 3 and 6 litre
Steel for 2, 3, 6 and 12.0 litre
Wire Sizes - Controller/Lite Controller/Timer
Contact Description Wire Type Size Strip Length
J1 & J2 Power Input
(Quick Connection)
Solid Wire /
Stranded Wire
24-14 AWG
(0.2 – 2.08mm2) 9-10 mm
J11 & J12 Fault Contact
(Screw Connection)
Solid Wire /
Stranded Wire
24-16 AWG
(0.2 – 1.5mm2) 5-6 mm
J10 All other inputs
(Quick Connection)
Solid Wire /
Stranded Wire
26-20 AWG
(0.13 – 0.52mm2)9-10 mm
Wire Sizes - Terminal Block
Contact Description Wire Type Size Strip Length
All All User Terminals
(Quick Connection)
Solid Wire /
Stranded Wire
20-14 AWG
(0.52 – 2.1mm2) 7.5-8.5 mm