Groeneveld TWIN Configuration guide

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

All rights reserved. No part of this manual may be copied and/or published by means of printing, photocopying,
microfilm or by any other means without prior written permission from 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.
This manual applies to the standard version of the product. Groeneveld cannot accept liability for any damage
arising from the use of specifications other than that supplied.
You are requested to contact Groeneveld technical service for information concerning adjustment, maintenance
work or repairs that is not described in this manual.
Whilst this manual has been prepared with the greatest possible care Groeneveld cannot accept responsibility for
any errors of the concequences of such errors.

TWIN General Manual
3
Date of Issue: March 2002
Table of contents
EG1701
Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7
1.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1.2. GROENEVELD Transport Efficiency B.V. - - - - - - - - - - - - - - - - - - - - - - - - 8
1.3. GROENEVELD Greasing Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
1.4. Twin Automatic Greasing Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2. Description of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
2.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
2.2. Assembling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
2.3. Description of the parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
2.3.1. Grease pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
2.3.2. Control unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
2.3.3. Distribution blocks and metering units - - - - - - - - - - - - - - - - 14
2.3.4. Grease pressure switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.3.5. The signal lamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.3.6. The operating mode push-button - - - - - - - - - - - - - - - - - - - - 15
2.3.7. The Twin display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.4. The greasing cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
2.4.1. Greasing cycle A - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
2.4.2. Greasing cycle B - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
3. Principle of operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
3.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
3.2. Pump unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
3.3. Metering units - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
3.4. Grease pressure switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
3.5. Control unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
3.5.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
3.5.2. The length of the greasing cycles - - - - - - - - - - - - - - - - - - - - 28
3.5.3. Maximum length of the pumping phase - - - - - - - - - - - - - - - 28
3.5.4. Length of the re-grease and pressure decrease phases - - - - - 29
3.5.5. Reaction of the system to grease pressure malfunctions. - - - 29
3.5.6. Repeating frequency of the flashing code - - - - - - - - - - - - - - 29
3.5.7. The log - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
3.6. Signal lamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
3.7. Twin display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
4. Operating instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
4.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
4.2. The operating mode push-button - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
4.3. Twin display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
4.4. The test push-button - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35
4.4.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35
4.4.2. The single-test cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35
4.4.3. The continuous-test cycle - - - - - - - - - - - - - - - - - - - - - - - - - - 36
4.5. The GINA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
4.5.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
4.5.2. Operating panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
4.5.3. Connecting and switching on the GINA - - - - - - - - - - - - - - - - 38
1. q^_ib=lc=`lkqbkqp

TWIN General Manual
Table of contents
4
Date of Issue: March 2002
EG1701
5. Maintenance instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -39
5.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
5.2. Overhaul - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
5.3. Bleeding the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
5.4. Re-filling the grease reservoir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
5.4.1. Use of the correct grease - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
5.4.2. Refilling the reservoir - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
5.5. Finding malfunctions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
5.5.1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
5.5.2. Recognising malfunctions - - - - - - - - - - - - - - - - - - - - - - - - - - 42
5.5.3. Malfunction finding table - - - - - - - - - - - - - - - - - - - - - - - - - - 43
5.5.4. Malfunction finding procedures - - - - - - - - - - - - - - - - - - - - - - 49
Explanatory word list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -53
Appendix A
Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -55

TWIN General Manual
5
Date of Issue: March 2002
Preface
EG1701
PREFACE
your efficiency is our challenge

TWIN General Manual
Preface
6
Date of Issue: March 2002
EG1701
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. The system
manual can also be used as a user manual.
This manual is not meant as a reference book when maintenance duties are carried
out. For these duties a separate maintenance manual is available at Groeneveld.
There is no extensive description of the GINA in this system manual. For this
description, refer to the maintenance manual.
The manual is built up of different sections, indicated by chapter numbers. The
numbering of the images re-starts with every new chapter.
Chapter 1, the introduction gives a description of Groeneveld and of greasing
systems in general.
Chapter 2 describes the whole Twin greasing system.
Chapter 3 provides an insight into the working of the various parts of the system.
Chapter 4 is the operating instructions for the greasing system.
Chapter 5 is the maintenance instructions of the greasing system.
The manual concludes with some appendices with checklists and technical
specifications.
At the back of the system manual you will find a glossary with an explanation of
the various technical terms.
In this manual, the following pictograms are used to bring an item to the user’s
attention or to notify the user.
ATTENTION:
Important supplementary information is brought to the users attention, so trying
to prevent problems occurring.
WARNING:
This pictogram notifies the user when the danger of physical injury or severe dam-
age to the apparatus by inadequate operation is threatened.

TWIN General Manual
7
Date of Issue: March 2002
Introduction
EG1701
1.
INTRODUCTION
your efficiency is our challenge

TWIN General Manual
Introduction
8
Date of Issue: March 2002
EG1701
1.1 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.
1.2 GROENEVELD Transport Efficiency B.V.
Investing in operational safety. With this thought in mind, Groeneveld was
founded in 1971. The present, international network is administered from its
headquarters in Gorinchem. Groeneveld strives for an expansion of its leading
position, achieved by the company’s solid image and customer-oriented policy.
Groeneveld employees form a team that daily works with great enthusiasm and
dedication for its customers. Extensive automation makes a high working rate
possible. The ISO 9001 standard is the basis for the guaranteed quality of
Groeneveld products. Frequent contact with clients and an extensive dealer
network guarantee the good name of Groeneveld. We know what the
entrepreneur needs today, not a ready-made product, but a custom-made solution
for automation.
New technologies offer new applications. Therefore Groeneveld has a large budget
available for the development of new cost-saving products. Our Research and
Development department not only collaborates with leading external
organisations, but also with leading manufacturers of vehicles and machinery.
In addition to the Twin automatic greasing system, Groeneveld also delivers
products such as:
• speed limiters
• board computer systems
• automatic oil level controllers
• reversing protection systems
• temperature recording systems
Groeneveld delivers a complete programme of cost-saving and comfort-enhancing
products.
figure 1.1 Groeneveld Head office

TWIN General Manual
9
Date of Issue: March 2002
Introduction
EG1701
1.3 GROENEVELD Greasing Systems
Groeneveld automatic greasing systems ensure the daily maintenance of
everything that has moving parts. They avoid unnecessary machinery wear and
down-time and thus save cost and prevent exasperation.
Groeneveld greasing systems are used by, for example, production companies,
machinery used in service industries, agriculture, ships, the offshore industry and
the transport industry.
In the following list are the most important advantages:
• increase of the service intervals, thus less unnecessary down-time;
• less wear of the greased parts because of accurate and constant greasing;
• reduced repair and replacement costs;
• reduced unexpected down-time;
• fewer production losses.
1.4 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. Every action is automatically carried out by the system. The user needs
only to refill the grease reservoir periodically.
The Groeneveld automatic greasing systems are designed with great care and
thoroughly tested to guarantee a long and fault-free life span, under the most
heavy operational conditions.
A well-functioning system requires:
• correct assembly;
• use of the prescribed type of grease;
• a periodic check of the functionality of the system.
The periodic check can easily be carried out at the same time as the normal
maintenance of the machine or vehicle. Moreover, because of the careful choice of
materials, the greasing system is nearly maintenance-free.
ATTENTION:
An automatic greasing system avoids the time-consuming manual greasing of
important parts. Remember, however, that there can be greasing points that still
have to be greased manually.

TWIN General Manual
Introduction
10
Date of Issue: March 2002
EG1701
Notes

TWIN General Manual
11
Date of Issue: March 2002
Description of the system
EG1701
2.
DESCRIPTION OF THE SYSTEM
your efficiency is our challenge

TWIN General Manual
Description of the system
12
Date of Issue: March 2002
EG1701
2.1 Introduction
Groeneveld has developed a double-line automatic greasing system especially for
the use of NLGI class-2 grease. The Twin system ensures that all the disadvantages
of the systems currently available for class-2 grease are eliminated.
The Twin system has all advantages of the Groeneveld single-line systems. This
means, for instance, that the system is expandible trouble-free with greasing points
that are installed afterwards. (extra machine equipment).
The advantages of the Twin system:
• ingenuous and fast assembly;
• modular expansion possible;
• parts of the system can (temporarily) be coupled or uncoupled;
• clear malfunction reports;
• registration of possible malfunctions;
• the grease dosage can easily be adjusted per greasing point to the needs of
that particular greasing point;
• the grease dosage per greasing point remains constant under all
circumstances;
• covering of the grease supply in the reservoir.
2.2 Assembling
A Groeneveld Twin greasing system generally consists of the following components
(see figure 2.1):
1. Electrically-driven plunger-pump with grease reservoir
2. Control unit (integrated in the pump housing)*
3. Distribution blocks
4. Metering units
5. Secondary grease lines
6. Grease pressure switch
1. Primary grease line A
2. Primary grease line B
* 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.

TWIN General Manual
13
Date of Issue: March 2002
Description of the system
EG1701
figure 2.1 Overview of the Twin automatic greasing system
2.3 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. When the grease pressure exceeds 250 bar during the pumping
phase, the relief valve will redirect the grease to the reservoir.
The maximum grease pressure will be exceeded when:
• a malfunction of the grease pressure switch, which is mounted in the system,
occurs;
• a malfunction in the cable of the grease pressure switch occurs.
The grease pressure switch is intended to end the pumping phase, as soon as the
minimum required grease pressure is reached.
The minimum-level switch
A level switch maintains the grease level in the reservoir. When the grease reaches
the minimum level, the level switch will notify the control unit. At the beginning
of every following greasing cycle a signal lamp in the cabin will flash as a warning
that the reservoir has to be refilled.
The test push-button
The grease system can be tested by starting one or more test cycles by means of the
test push-button on the pump unit. This button also can be used to reset the
control unit.
6
1
3
5
4
2
Cycle A
Cycle B

TWIN General Manual
Description of the system
14
Date of Issue: March 2002
EG1701
2.3.2 Control unit
The electronic control unit steers and controls the course of the greasing cycles. All
system- and program-parameters are stored in it. The control unit processes
malfunction reports, gives possible alarm reports and automatically records a log.
All relevant incidents will be stored in the log.
The system- and program-parameters can be
viewed and altered using the GINA program
unit (Groeneveld tester for INstallation and
Analysis, (see figure 2.2). The log can also be
viewed with the GINA. A GINA is not delivered
as standard with a greasing system.
The GINA and the log together make sure that
the cause of a malfunction can be discovered
both quickly and efficiently, so reducing
service- and repair times to a minimum.
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.
The metering units are mounted on
a stainless steel or brass
distribution block per group (see
figure 2.3). These priimary grease
lines are connected. The blocks are
deliverable with 2, 3, 4, 5, 6, 7, 8, 9,
12, 14, 18, 20, 21 or 22 ports (exits).
Greasing points are connected to
these ports through metering units
and secondary grease lines. Unused
ports are sealed with a blind plug.
A grease pressure switch can also
be mounted into one of the exits.
Because of their closed
construction the metering units are
exceptionally well suitable for use
in dirty and dusty environments.
figure 2.2 The GINA
1. metering unit number
2. Part number
3. Production week/-year
figure 2.3 Distribution block with
metering units

TWIN General Manual
15
Date of Issue: March 2002
Description of the system
EG1701
The metering units and distribution blocks are made of brass or stainless steel. The
various metering units are distinguished from each other using numbers (see figure
2.3). The table below is an overview of the various metering unit numbers and their
grease capacity.
2.3.4 Grease pressure switch
The grease pressure switch notifies the control unit that sufficient pressure has
been built up during the greasing cycle (in the pumping phase). When the required
pressure is not reached in the maximum adjusted pumping time, an alarm follows.
Preferably the grease pressure switch is mounted on the distribution block, located
the farthest from the pump. This is done to be sure that the required grease
pressure is also reached at the distribution block. When for practical considerations
the switch is placed somewhere in the middle or at the beginning of the greasing
system, a switch with a higher switch-pressure is applied. pressure switches are
delivered with switch pressures of 100, 125, 150 or 175 bar.
2.3.5 The signal lamp
The signal lamp uses flash codes to indicate the status of the greasing system and
malfunctions. The signal lamp (possibly combined with the operating mode push-
button) is preferably mounted in the field of vision of the driver.
2.3.6 The operating mode push-button
Using the operating mode push-button, the intensity with which greasing takes
place can be increased or decreased, depending on the circumstances under which
the vehicle or machine is used.
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.
The display is also equipped with a push-button with which another operating
mode can be chosen at any moment.
Metering
unit
number
Grease capacity
(cm3) per greasing
cycle
0
1
2
3
4
5
6
7
8
8,5
9
10
0,025
0,050
0,100
0,150
0,200
0,250
0,300
0,350
0,400
0,700
1,000
2,000

TWIN General Manual
Description of the system
16
Date of Issue: March 2002
EG1701
2.4 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. The total
greasing cycle has a predetermined time; however, the length of the four phases
depend on the circumstances. The different greasing cycles and phases are
discussed below.
figure 2.4 Overview of the various phases of the greasing cycles
2.4.1 Greasing cycle A
The pumping phase
The greasing cycle begins with a pumping phase. In this phase the grease is pumped
from the reservoir, through primary grease line A, to the distribution blocks. The
pumping phase ends when the pressure at the pressure switch reaches a
predetermined level. The time needed to reach that predetermined pressure
depends on various factors as temperature, grease consistency (thickness) and the
dimensions of the greasing system. The duration of the pumping phase is therefore
not directly adjustable.
During the pumping phase, the metering units press a certain amount of grease
(the dosage) through the secondary grease lines to the greasing points.
The re-grease phase
The re-grease phase follows the pumping phase; a period in which the pressure in
the primary grease lines is maintained at a certain pressure. During the re-grease
phase, the metering units can deliver the grease dosage, which (for various reasons)
was not yet delivered during the pumping phase. The duration of the re-grease
phase depends on the duration of the pumping phase. This dependency is
expressed in the parameter bmf, bleeding multiplication factor.
Example: When the bmf is 1, the re-grease phase is 1/10th of the length of the
pumping phase. When the bmf is 10, the re-grease phase is 10/10th of
the length of the pumping phase.
Cycle A Cycle B
pump
5/2 valve
pressure path
main line A
pressure path
main line B
re-grease
phase
pressure
decrease
phase
pause
phase re-grease
phase
pressure
decrease
phase
pumping pause
phase
pumping

TWIN General Manual
17
Date of Issue: March 2002
Description of the system
EG1701
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.
The duration of the pressure decrease phase is equal to that of the re-grease phase
and therefore proportional to the duration of the pumping phase. When the
greasing system needs more time to build up the required grease pressure (because
of low temperature or grease with a high viscosity), the system will also need more
time to decrease that same pressure.
The pause phase
The pause phase is the period between the pressure decrease phase and the
beginning of the next pumping phase. The length of the pause phase is equal to
the predetermined cycle-time minus the length of the other phases. When the
cycle-time is adjusted too short to carry out a complete greasing cycle, the program
will ignore the cycle-time. The pumping-, re-grease- and pressure decrease phase
will be carried out completely. However the pause phase will be omitted, because
the predetermined cycle-time is exceeded. The greasing system begins directly with
the first phase of the next greasing cycle.
2.4.2 Greasing cycle B
Greasing cycle B begins when the control unit restarts the pump. During pumping
phase B and re-grease phase B, the control unit still has the 5/2 valve energized,
causing the pump to be connected to primary grease line B. Primary grease line A
is shut off from the pump during these phases and connected to the reservoir.
During the phase B pressure decrease, the control unit de-energizes the 5/2 valve,
so the grease pressure in the grease line decreases and the grease flows back to the
reservoir.

TWIN General Manual
Description of the system
18
Date of Issue: March 2002
EG1701
Notes

TWIN General Manual
19
Date of Issue: March 2002
Principle of operation
EG1701
3.
3. PRINCIPLE OF OPERATION
your efficiency is our challenge

TWIN General Manual
Principle of operation
20
Date of Issue: March 2002
EG1701
3.1 Introduction
In this chapter the principles of operation of the various parts of the Twin
automatic greasing system are discussed. The pump unit, metering units, grease
pressure valve, control unit, signal lamp and display are discussed.
3.2 Pump unit
The Twin pump unit consists of various parts. These parts are shown in figure 3.1.
figure 3.1 pump unit assembly
1. grease follower piston
2. grease reservoir
3. stirring gear
4. cam
5. cylinder and plungers (3x)
6. 5/2 magnetic valve
7. primary grease line ‘A’ coupling
8. primary grease line ‘B’ coupling
9. mechanical transmission
10. control unit
11. electro-motor
12. test push-button
13. filler coupling with grease filter
14. relief valve
15. follower piston guide
16. electric connector
17. minimum level switch
18. bleeding- and grease overflow channel
19. bleeding- and grease overflow channel at right side of
pump, connected to the grease overflow channel in the
follower piston guide (nos. 15 and 18)
1
2
3
4
5
6
7
8
910
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
1
2
3
4
5
6
7
8
9101112
13
14
19
16
17
15
18