Bijur Delimon WS-E User manual

1 BIJUR DELIMON INTERNATIONAL BA_2018_1_GB_WSE
Operating manual
Chain lubrication
aggregate WS-E
BA_2018_1_GB_WSE

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INDEX
1. General ........................................................ 2
2. Safety .................................................... 2 – 3
3. Application .................................................. 4
4. Design and Function ......................... 4 – 5
5. Dimensions ................................................. 6
6. Technical Data ........................................... 8
7. Unit configuration and coding ............. 9
8. Assembly, installation and
commissioning ............................... 10 - 13
9. Maintenance and servicing ................ 13
10. Spare parts ............................................. 14
11. Storage and transport ........................ 14
12. Suitable system components ............ 14
13. Plates ........................................................ 14
1. GENERAL
Prior to start up, we recommend to read
these operating instructions carefully as we
do not assume any liability for damages and
operating troubles which result from the
nonobservance of these operating
instructions!
The below described pump is designed for
use in centralized lubrication systems or to
supply downstream lubrication systems.
Any use beyond the applications described
in these operating instructions is
considered to be not in accordance with the
product’s intended purposes. The
manufacturer is not to be held responsilbe
for any damages resulting from this: the
user alone bears the corresponding risk.
As to figures and indications in these
operating instructions we reserve the right
to make technical changes which might
become necessary for improvements.
The copyright on these operating
instructions is kept reserved to the
company DELIMON. These operating
instructions are intended for the erecting,
the operating and supervising personnel.
They contain regulations and drawings of
technical nature which must not –
completely or partially - be distributed nor
used nor communicated to others without
authorization for competition purposes.
Company address, spare parts and
service address
DELIMON GmbH
Arminstraße 15
D-40277 Düsseldorf
Phone [phone]
Fax [phone]
Branch office
Am Bockwald 4
D-08344 Grünhain-Beierfeld
Email: [email protected]
www.bijurdelimon.com
2. SAFETY
These operating instructions contain
fundamental instructions which are to be
observed during erection, operation and
maintenance. Therefore it is absolutely
necessary for the fitter and the
competent qualified staff/user to read
these operating instructions before
installation and start-up. The operating
instructions must be available at all times
at the place of use of the
machine/system.
Not only the general safety instructions
stated under this main point “safety“ are to
be observed, but also the other specific
safety instructions stated under the other
main points.
2.1 Identification of safety warnings in
the operating instructions
The safety warnings contained in these
operating instructions which, if not
observed, may cause dangers to people, are
specially marked with general danger
symbols
safety sign according to DIN
4844, warning about a danger spot, in case
of warning about electric voltage with
safety sign according to DIN
4844, warning about dangerous electric
voltage.
In case of safety instructions which, if not
observed, may cause damage to the
product and its function, the word
ATTENTION
is inserted.
Instructions that are directly attached to
the machine, as for example
rotational direction arrow
identifications for fluid connections
must be observed at all events and
maintained in a fully legible condition.
Note: There is an increased skid risk in
case of spilled/leaked out lubricants.
They are to be removed at once
properly.
Safety sign according to DIN
4844, warning about skid risk.

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2.2 Personnel qualification and training
The operating, maintaining, inspecting and
erecting personnel must have the
appropriate qualification for such work.
Area of responsibility, competence and
supervision of the personnel have to be
regulated by the user. If the personnel do
not have the necessary knowledge, they
have to be trained and given instructions.
This can be effected, if necessary, by the
manufacturer/supplier on behalf of the
user of the machine. Furthermore, the user
has to make sure that the contents of the
operating instructions are fully understood
by the personnel.
2.3 Dangers in case of nonobservance of
the safety instructions
The nonobservance of the safety
instructions may result in hazards to
persons, to the environment and to the
product. The non-observance of the safety
instructions may lead to the loss of any
claims for damages.
In detail, the nonobservance may for
instance lead to the following hazards:
Failure of important functions of the
product/system/machine
Failure of prescribed methods for
maintenance and repair
Harzard to persons by electrical,
mechanical and chemical influences
Hazard to the environment by the
leakage of dangerous substances
2.4 Safety conscious working
The safety instructions stated in these
operating instructions, the existing national
regulations as to the accident preventation
as well as possible internal working,
operating and safety rules of the user are
to be observed.
2.5 Safety instructions for the
user/operator
If hot or cold product or machine parts
lead to dangers, these parts have to be
protected against touch.
Protection against touch for moving
parts (e. g. coupling) must not be
removed when the machine is in
operation.
Leakages (e. g. from the shaft seal) of
hazardous goods to be delivered (e. g.
explosive, toxic, hot) are to be removed
in such a way that there is no danger to
persons and environment. Legal rules
are to be observed.
Hazards caused by electrial power are
to be excluded (for details please refer
for instance to the rules of the VDE and
the local power supply companies).
2.6 Safety instructions for maintenance,
inspection and installation work
The user has to take care that all the
maintenance, inspection and installation
work is executed by authorized and qualified
skilled personnel who have informed
themselves adequately by thoroughly
studying the operating instructions.
Basically, work on the machine is only to be
carried out during shut-down. It is
obligatory to observe the shut-down
procedure described in the operating
instructions.
Pumps or pump aggregates that deliver
media being hazardous to health have to be
decontaminated. Immediately after
completion of the work, all safety and
protective equipments have to be
reinstalled and/or reactivated.
Advice: When working with compressed
air, do wear glasses.
(DIN 4844 – Use breathing mask)
Advice: Observe EC-Safety Data Sheet
for materials of consumption and
additives used and use personal
protective equipment.
2.7 Unauthorized conversion and
manufacture of spare parts
Conversion or modifications to the product
are only permitted when agreed with the
manufacturer. Original spare parts and
accessories authorized by the
manufacturer serve to ensure safety. The
use of other parts may render the liability
for consequencial losses null and void.
2.8 Unacceptable modes of operation
The operational reliability of the product
supplied is only guaranteed if the product is
used in accordance with its intended
purposes as per section 1 - General - of the
operating instructions. The limiting values
specified in the data sheet must on no
account be exceeded.
2.9 Guidelines & standards
1., 2. and 3. guideline (see data sheet:
R&N_2009_X_GB)
2.10 Notes on environmental protection
and waste disposal
In correct operation with lubricants, the
components are subject to the special
requirements set by environmental
legislation.
The general requirements for lubricants
are specified in the respective safety data
sheets.
Used lubricants are hazardous forms of
waste and therefore require special
supervision in the sense of § 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).
The devices or components contaminated
with lubricant must be disposed of by a
certified waste management company.
Records of proper waste management must
be filed in conformance to NachwV
(Ordinance on Waste Recovery and Disposal
Records).
2. SAFETY

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GENERAL PRODUCT FEATURES
Gear wheel pump unit with 1.2 litre delivery volume
Primary field of application in WS-E chain lubrication systems for the automatic lubrication of chains, joints, rollers,
hinges etc.; another possible field of application is the oiling of built-in parts (engine crankshaft)
Suitable for mineral oils with an operating viscosity of between 40 and 900 mm
2
s
-1
(cSt)
Operating pressure of up to 30 bar (ensured via an internal pressure relief valve)
Up to 7 lubrication cycles (depending on the viscosity) can be performed per second
Surface coating DELIMON Standard RAL 7004 (Signal grey) C2M
3. APPLICATION
The WS-E gear wheel pump unit is primarily used in single-line systems with dynamic dividers of type ZE-E, and when
connected in this way, the unit allows for the targeted and metered lubrication of moving lubrication points by means of a
flying drop (up to 7 drops per second, depending on the viscosity).
Another possible application consists of use with static single-line dividers or use as a delivery pump in connection with a
solenoid valve at the end of the main line.
4. STRUCTURE AND MODE OF ACTION
The WS-E chain lubrication unit essentially consists of:
1. 1 outlet
2. Three-phase or alternating current motor
3. Gear wheel pump
4. Solenoid valve for direct or alternating current
5. Tank (4-litre metal tank or 12-litre aluminium tank as standard)
6. Min. float switch
Chain lubrication unit - schematic presentation of the chain lubrication unit
The WS-E gear wheel pump is available with 4-litre or 12-litre tank sizes as standard.
Pos. 1 (outlet)Pos. 2 (motor) Pos. 4 (solenoid valve)
Pos. 5 (tank)
Pos. 6 (float switch) Pos. 3 (gear wheel pump)

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4. STRUCTURE AND MODE OF ACTION
Starting the power supply to the motor causes the oil inside the tank to be sucked in by the flange-mounted gear wheel pump,
and and to be delivered to the solenoid valve from the pump body via the external tube. The oil is delivered back into the tank
via the de-energised solenoid valve, and is almost entirely de-pressurised.
When the power supply to the solenoid valve is started, the valve is mechanically switched and the oil cycle is interrupted.
The oil is delivered abruptly in the direction of the outlet, and if the unit is being used in the WS-E system, then the oil can serve
the following ZE-E dividers. These then deliver their pre-stored quantity of lubricant to the lubrication points at high speed via
the spray nozzles (in the form of a targeted drop).
Interrupting the power supply to the solenoid valve causes the valve to be mechanically switched back to its starting position.
The pressure in the main line drops, and the oil cycle described above begins again as long as the motor is being supplied with
power. In de-energised state, the solenoid valve has connected all of the connections to one another. However, the special
design within the solenoid valve ensures that the connected main line cannot run empty and that it retains residual pressure.

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5. DIMENSIONS (mm)
WS-E 4 litre
WS-E 12 litre

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6. TECHNICAL DATA
Technical specifications of the unit
Operating pressure max. ................................................................................................................................................................ 30 bar
Permissible ambient temperature range ........................................................................................................................... 0 to +40°C
Delivery volume at a rated motor speed of 3000 rpm .............................................................................................. 1200 cm3/min
Delivery volume at a rated motor speed of 3600 rpm .............................................................................................. 1440 cm3/min
Tank volume ........................................................................................................................................................................... 4 or 12 litres
Suitable lubricants with a mineral oil base:
Mineral oil ............................................................................................................................. 40…900 mm2s-1 operating viscosity
Synthetic oils, solid additives and solvents ................................................................................................................ on request
Connectible pipelines:
Outlet .......................................................................................................................................................................................... Ø 6 mm
Dimensions ............................................................................................................................................................. see images on page 6
Weight:
Unit with 4-litre tank (steel) ................................................................................................................................................. 12.5 kg
Unit with 12-litre tank (aluminium) ....................................................................................................................................... 5.6 kg
Technical specifications of the motor (see appendix for datasheets):
Alternating current motor (art. no.: 76911M358) ........................................ 1/N/PE AC 50Hz 230V, 0.18kW, 3000 rpm
Three-phase motor (art. no.: 769115213)........................................................... 3/PE AC 50Hz 400V, 0.18kW, 3000 rpm
UL alternating current motor (art. no.: 76911M293) .................................. 1/N/PE AC 60Hz 115V, 0.18kW, 3600 rpm
UL three-phase motor (art. no.: 76911M090).................................................... 3/PE AC 60Hz 115V, 0.18 kW, 3600 rpm
Technical specifications of the solenoid valve (see appendix for datasheets):
Solenoid valve (art. no.: 38152M129) ..................................................................................................................... DC 24V, 24W
Solenoid valve (art. no.: 381521133)...........................................................................................1/N/PE AC 50Hz 230V, 19VA
Technical specifications of the float switch (see appendix for datasheets):
For 4-litre tank, operating voltage 10..48V (art. no.: 39161S088)
Max. switching current ................................................................................................................................................................ 0.5 A
Max. switching capacity ............................................................................................................................................................... 5 VA
Switching outputs for ...................................................................................................................... advance warning and empty
For a 4-litre tank, max. operating voltage 250V (art. no.: 39161S089)
Max. switching current ................................................................................................................................................................ 0.5 A
Max. switching capacity ............................................................................................................................................................. 10 VA
Switching outputs for ...................................................................................................................... advance warning and empty
For a 12-litre tank, max. operating voltage 250V (art. no.: 391611113)
Max. switching current .................................................................................. at 24V = 1A; at 120V = 0.5A; at 230V = 0.261A
Max. switching capacity .............................................................................................................................................................. 60VA
Switching outputs for ............................................................................................................................................................... empty

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6. TECHNICAL DATA
Wiring diagram for terminal box 76922-7743
Connection dimensions: 113 mm x 52 mm
Central drilled holes with
bottom of housing

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7. UNIT CONFIGURATION AND CODING
WSE 01 A 02 24 B 03
Coding example results with accessories:
WSE01A0224B03
WSE01A0123B04 WSE01A0223A05 WSE01A0124B06
Number of outlets:
1 outlet - 01
Revision A
(no selection)
Drive type:
Alternating current motor 230V, 50Hz - 01
Three-phase motor 400V, 50Hz - 02
UL alternating current motor 115V, 60Hz - 15
UL three-phase motor 115V, 60Hz - 12
Cycle valve:
Direct current DC 24V - 24
Alternating current AC 230V - 23
Accessories:
None - 00
Float switch for 4 litre, 2x min, 12-48V - 01
Float switch for 4 litre, 2x min, 250V - 02
Float switch for 12 litre, 1x min, 250V - 03
Terminal box (12-litre version only) - 04
Automotive system (PSA) with filling via sealing nipple for 4-litre version - 05
Automotive system (PSA) with filling via sealing nipple for 12-litre version - 06
Codin
g
exam
p
le:
Tank:
4 litre, metal - A
12 litre, aluminium - B

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8. ASSEMBLY, INSTALLATION AND COMMISSIONING
Assembly must only be performed by qualified specialist personnel. Suitable standard assembly tools must
be used.
Contact our Service department if necessary. Our service technicians or assembly supervisors are available to help with
assembly, training and instruction either on a one-off basis or for longer periods to be settled by daily rate.
Installation position and mounting:
In the 4-litre version, the pump unit is preferably attached to a wall via four mounting holes with Ø 7.5, using hexagon nuts
M6 x 40 and washers. Floor mounting is also possible using the 4 rubber-metal buffers underneath the tank.
In the 12-litre version, the pump unit can only be floor-mounted. There are 4 threaded holes (M8x15) in the feet for this
purpose.
The fixing screws are not included in delivery as standard, and must be ordered separately as accessories.
oWhen mounted onto a wall, the pump unit must always be in a vertical installation position,or when floor-mounted, the
motor must always be facing upwards.
oThe unit must be mounted tension-free onto a flat surface.
Positioning the pump unit
When installing the pump unit, it must be ensured that it is positioned as closely and centrally as possible to the connected
lubrication points. In connection with the ZE-E lubricant divider, it must also be ensures that the distance between the pump
unit and the furthest ZE-E divider does not exceed 5 m.
oThe pump unit must be easily accessible for maintenance and inspection purposes.
Assembling the pipelines and tubes:
oArrange the tubing such that ventilation is possible (with a slight incline from the pump unit to the dividers).
oOnly ever use clean oils!
oDirt particles can cause system failure!
oClean conditions must be ensured during assembly.
oThe pipes must be checked for impurities (e.g. chippings) prior to connection to the pump unit
and must be flushed out if necessary.
Commissioning:
The pump unit itself does not require any ventilation, although when used in combination with the ZE-E dividers, the system
will need to be ventilated when the pump unit is re-installed or replaced. The ventilation process is described below.
oMake sure that all connected pipelines are correctly fitted.
oFill the oil tank before commissioning the pump unit or lubrication system!
ATTENTION
ATTENTION

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oCheck whether the motor rotation direction is correct when the power supply is turned on. (Arrow on the motor)
oThe oil is circulated via the opened solenoid valve (in a de-pressurised state).
oRemove the plug on the solenoid valve in order to prevent pulsing during the adjustment phase.
Solenoid valve

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oThen carefully ventilate the pipelines by undoing the screw plug on the divider manifold. A container must be placed
underneath the open divider manifold in order to ensure that the surrounding area is not contaminated by escaping oil. If
multiple divider manifolds are being used within the system, then ventilation must be performed starting with the nearest
and ending with the furthest divider manifold.
oAs soon as oil with no air bubbles can be seen, the screw plug should be re-tightened.
oThe throttle screw on the solenoid valve must then be turned very slowly in a clockwise direction to close it until all ZE-E
divider release a fine, continual stream of oil as a result of the pressure build-up in the main line. It must be ensured that
all dividers release a continual stream of oil, or at least a steady flow of drops. The individual dividers will deliver the oil
on a staggered basis.
If not all of the dividers worked the first time (no visible functioning), then the procedure must be repeated by turning
the throttle screw anti-clockwise all the way back against the locking screw, and then closing it again by slowly turning in
a clockwise direction. The dividers will not start working at the same time; start-up will usually be staggered.
oIf the pipelines, elements and nozzles are perfectly ventilated (a fine, continual stream of oil has come out of each
nozzle), then the throttle screw must be fully opened by turning in an anti-clockwise direction (fully open = touching the
locking screw).
oThe disconnected plug must be re-connected to the solenoid valve.
oA lubrication cycle must then be performed. This is performed by triggering impulses in quick succession on the proximity
switch, either by damping the electronic field or by repeatedly breaking the light barrier.
Screw plug
ZE-E divider
Divider manifold
Throttle screw
Locking screw

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oMake sure that the pump unit does not exceed the permissible operating pressure. The pressure relief valve may need to
be re-adjusted (30 bar). For information on adjusting the pressure relief valve, see
item 9. Maintenance and servicing
oIt is recommended that a pressure gauge be used to monitor the system pressure at a suitable point (directly behind the
unit). The pressure should be monitored via a miniature measuring connection or a pressure switch (on the end of the
main line behind the furthest divider).
oThe system is now ready for operation.
oWhen the system is running, adjust the position of the nozzles and the response pressure of the proximity switch until the
drops of oil accurately reach the required lubrication points. If necessary, hold a piece of paper in front of the nozzle
opening to check whether a drop has been released.
oOnce assembly is complete, check that the system is leak-tight and is working perfectly at each installed divider and
lubrication point.
Continuous operation:
The pump unit is designed for continuous operation. It must be ensured that the specified operating pressure and
temperature range are complied with during the entire operating phase. Only ever use approved lubricant that is free from
any contamination.
Disassembly:
The pump unit must only be disassembled when at a standstill and when the system is de-pressurised.
9. MAINTENANCE AND SERVICING
There is no need for any particular maintenance or servicing work. The pressure build-up in the pump must be checked at
regular intervals using a pressure gauge, and must be corrected as necessary using the pressure relief valve.
WS-E pressure relief
Remove the screw plug and use a standard screwdriver to turn the setting screw in a clockwise direction to increase the
pressure. Turning the setting screw in an anti-clockwise direction reduces the pressure. Please note that the maximum
permissible operating pressure is 30 bar. Once the pressure relief valve has been adjusted, the screw plug must be screwed
back in again.
Setting screw
Screw plug

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10. SPARE PARTS
WSEETA0001 – Spare parts kit - 4-litre gear wheel pump
WSEETA0002 – Spare parts kit - seals
WSEETA0003 – Spare parts kit - 12-litre gear wheel pump
WSEETA0004 – Spare parts kit - 12-litre gear wheel pump with tank cover and motor
WSEETA0005 – Spare parts kit - 12-litre tank
WSEETA0006 – Spare parts kit - 14-litre gear wheel pump with tank cover
11. STORAGE AND TRANSPORT
The unit should ideally be stored and transported vertically in order to ensure that it is not contaminated by lubricant
residues in the tank. Other than that, there are no other particular transport or storage regulations.
12. SUITABLE SYSTEM COMPONENTS
The following distributor types are primarily used in combination with the pump unit:
ZE-E dividers (see ZE-E product documents).
13. PLATES
Company sign Type plate