Groeneveld Ac3 User manual

GROENEVELD—NORTH AMERICA

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AC3InstallaonManual

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GVNA_IM003.1_JFAC3OperaonandMaintenance

AC3 Pump Info

MaximumWorkingPressure:1740psi(120bar,12MPa)

Maximumoperangtemperature:122°F/50°C

*(Notethatoperangoverthemaximumtemperaturewilleﬀectlifeofthepump)*

Minimumoperangtemperature:‐40°F/‐40°C(withSAE80/90Oil),5°F/‐15°C(withgrade2grease).

IPRang:IP66

Voltage:12Vor24V

PowerRang:2A

FuseRang:2A

MaxLineLengthperInjector:50(15m)

ThisprintandtheideasandprinciplesrepresentedontheprintarethepropertyofGroeneveldLubricaonSoluons.Thisprintisnottobecopiedorreproduced(evenextracts)

withoutpriorwrienconsentofGroeneveld.Everycarehasbeentakentoensuretheaccuracyoftheinformaoncontainedinthispublicaonbutnoliabilitycanbeacceptedfor

anylossordamagewhetherdirect,indirectorconsequenalarisingoutoftheuseoftheinformaoncontainedherein.

INSTALLATION

OnlyinstalltheGroeneveldACSystemifyouaresuitablyqualiﬁed.

Readtheinstallaoninstruconsinfullbeforecommencing

installaon.IfindoubtcontactGroeneveldon+1(937)2764507

PERSONAL PROTECTIVE CLOTHING

Youmustwearappropriateprotecveequipmentwhenoperang

andservicingtheequipment,thisistoprotectyoufromserious

injury.

Thisequipmentincludesbutisnotlimitedto:

 Protecveeyewear.

 Respirators,protecveclothingandglovesasrecommendedby

theLubricantmanufacturer.

PLASTIC PART CLEANING SOLVENT HAZARD

Manysolventscandamageplascpartsandcausethemtofail,which

couldcauseseriousinjuryorpropertydamage.

 Useonlycompablecleaningproducts.

ENVIRONMENT

EnsurethatallLubricantsareresponsiblydisposedofinaccordance

withthemanufacturersMSDSsheetsandlocalregulaons.

WARNING

AC3OperaonandMaintenanceII

Installaon Warnings

Please retain these safety and operaon instrucons for future reference.

EC Declaraon Of Conformity

IIIAC3OperaonandMaintenance



EC Declaraon of Conformity

InaccordancewithISO/IEC17050‐1:2010

WeGroeneveldUK

Of85aStModwenRd,ParkwayIndustrialEstate,

Plymouth,Devon,UnitedKingdom,PL68LH.

Iherebydeclarethat:

Equipment: AC3XXX/XMul‐LineLubricaonSystem

InaccordancewiththefollowingDirecve(s):

2004/108/EC  TheElectromagnecCompabilityDirecve

2006/42/EC  MachineryDirecve

UNECEReg.10.05 AutomoveElectromagnecCompabilityDirecve

2011/65/EC  RestriconofCertainHazardousSubstances

Hasbeendesignedandmanufacturedtothefollowingspeciﬁcaons:

97/23/EC,BSENISO50498:2008

Iherebydeclarethattheequipmentnamedabovehasbeendesignedtocomplywith

therelevantseconsoftheabovereferencedspeciﬁcaons.Theunitcomplieswith

allessenalrequirementsoftheDirecves.



Signed:



Name: RichardButler   Posion: DivisionalManagingDirector

Doneat: Plymouth,UK   Date: 04/01/2016

DocumentRef:ISF336Issue4

Installaon

AC3OperaonandMaintenance

Pump Clearance Requirements

AC3 pump clearance:

1

Mounng Hole Dimensions

AC3 standard mounng posions:

Select a suitable mounting point for the pump on the chassis, preferably in a position where it is protected from

debris. Ensure adequate clearance for the looming, access to the override button and refilling clearance is made

(see images on the following page).

Do not mount the pump on to ancillary equipment, such as the battery housing or cover.

Using the pump mounting template, supplied with the pump, position and drill the bracket holes (mounting —

positions detailed as above). Use bolts, nuts and spring washers supplied to securely mount the pump in position.

AC3OperaonandMaintenance

Pumping Units

Installaon

Standard Pumping Units for AC3 Pumps.

Part No. ‘F’ No. Output/stoke Color Outlet Size

78033‐PL F800091 0.010cc Red

Ø4mmOD

PushType

78034‐PL F800092 0.015cc Green

78035‐PL F800093 0.025cc Yellow

78036‐PL F800094 0.040cc Blue

78037‐PL F800095 0.060cc Grey

78038‐PL F800096 0.100cc Black

34237‐402 F800108 N/ABlankingPlug

MaximumOutputpressure

fromeachPumpingUnit 1740PSI/120Bar

Output pressure

Making the Looms

ThislubricantdistribuonlinesshouldbemadeupofGroeneveldØ4mm,semi‐rigid,nylontubing.Itisrecommendedthatthe—

tubingispre‐ﬁlledwithgreasetosaveontherequirementtoprimethesystemonceinstalled.

Fromthepumpposionestablishthemostconvenientrouteforthelubricaonlines.Itmaybepreferredtogroupthelinesinto

loomsdependingonpumplocaonandquantyandposioningofthegreasepoints.Ifgroupingthelines,intolooms,allow‐

suﬃcientlengthforconnecontothebulkheadoutletconnectorsandthebearings,makinganallowanceformovementonthe

machinery.Inconjunconwiththe‘Installaon Record’sheet(seepage16),ﬁtthenumberidenﬁcaonsleevestothelinesatthe

pumpandbearingends.Theloomshouldbeprotectedalongitslengthwiththeconduit/spiralbinding/sleevingand/ortape(for

partnumberssee‘Accessories’ onpage13).

Installaon: 

Workingfromthefurthestpointfromthepump,feedthelubricaonlinesthroughthemachinefollowingexisngmachineservices,

wherepossible.Ensurethatthelubricaonlinesareposionedtoﬁtthebearingﬁngs.Whereabearingisonamovingpart,‐

ensurethatthelineissuﬃcienttoallowforfullmovement.Toavoidrubbingorfriconwithmovingparts,grommetsorprotecve

sleevingshouldbeused.Also,dependingontheseverityofmovement,compressionﬁngsmaybepreferredatthebearingpoints.

Connecng the lines:

Cuteachlubricaonlinetolengthensuringaclean,squarecutisachieved.Connecttothebearingusingpushﬁtorcompression

connectors.ENSURE TUBING IS PUSHED FIRMLY INTO CONNECTOR. TEST ASSEMBLY BY PULLING FIRMLY ON THE LINE AFTER

INSTALLATION.UsingtheSystemSpeciﬁcaonSheetconnecttheloomtocorrespondingnumberedpumpingunits.When‐

runningthetubingintothepumpingunits,togivetheloomstrengthandrigidity,thetubesshouldbeclippedtogethertoforman

arrangementwithanoﬀsetfromthepumpof50to60mm(2”‐2‐1/2”).Thestarngpointfortheloomcanbeasrequired.

Starngwiththeboomrowofoutletsandpumpingunit“1”,theloomshouldthenrunaroundthepump,thenontoconnect

withthenextrowofpumpingunitssothattheloomtakestheformofaspiral,andsoonunlallpumpingunitsareconnected.

Tubesshouldbekepttogetherwithe‐clipsatintervalsofevery6pumpingunits.Theloom,orlooms,canthenberoutedonto

thechassisasrequired.



Note:Alldamagedpipeworkshouldbereplacedusinggenuinespareparts,failuretodosocancausesystemmalfunconsand

safetyissues.

2

AC3OperaonandMaintenance

Installaon

Wiring Informaon

InstallaonoftheACrangeofpumpsshouldideallyincorporatedirectconneconstothevehicleignionsystem.

Thisprovidesautomaclubricaonwhenevertheignionisswitchedon.

Amemory,builtintothepumpsprintedcircuitboard,removesthepossibilityofover‐lubricaononashorttrip/

mul‐dropoperaon.

2AFuse

REDToBaery+

ViaIgnion

Chassisground

Chassis

ground

ExisngVehicle

electricalcircuit(s)

3

AC3 Electrical Schemac

AC3OperaonandMaintenance

Operaon

PCB Adjustments

4

Rotaryswitchset

toposion‘0’.

24VPCB(83344‐107):

Rotary

Switch Posi-

on

Seng *(Pump runs for 1 minute 8

seconds aer delay period has

elapsed).

0* ConnuousOperaonat1.8rpm

1* ConnuousOperaonat0.9rpm

2* 3minutesdelay

3* 7minutesdelay

4* 11minutesdelay

5* 15minutesdelay

6* 19minutesdelay

7* 24minutesdelay

8* 30minutesdelay

9* 36minutesdelay

PumpCyclemesandprogrammingtable:

TheACrangeofpumpsarefactorysetto—

connuousoperaonat1.8rpm(seng0onthe

PCB),unlessotherwisespeciﬁed.However,ifthe

sengneedstoadjusteditcanbeeasilychanged

followingtheprocedurebelow:

ToaccesstheinternalPCBandadjusttherun

sengs,viatherotaryswitch.

1)Disconnectpowertothepump.

2)Removeblankingplugfrommotorhousingusing

an8mm(or5/16”)HexKey(seeFig.1and2).

MakesuretoretainO‐ringontheblankingblank.

3)AccessPCBandadjustrotaryswitchasrequired

usinga3/32”(2.4mm)ﬂatheadscrewdriver(See

Fig.3andsee24VPCB(83344‐107)imagebelow

forrotaryswitchlocaon).

4)Re‐assemble,ensuringtheO‐ringiscorrectly

ﬁedontheblankingplug.Torqueto5.0Nm

(3.7lbf.).

5)Reconnectpowertothepump.



Fig.2

Fig.3

Fig.1

Fig.1A

AC3OperaonandMaintenance

Operaon

5

System Operaon and Tesng



Thesystemhasbeendesignedtobemaintenancefree,buttesngthesystemisalwaysrecommendedto

diagnoseanyfaultsortocheckthegeneralworkingcondionofthesystem.

Thelubricaonprocessstartsaereithertheignionisswitchedon(ifsettoconnuousrunmodeandthepump

isonlypoweredwhentheignionison)oraerthealloeddelayme(ofthealreadyprogrammedpump)has

elapsed.Thepumpwillrunfor1minuteand8seconds(equivalenttoonefullcamrevoluon)anddelayforthe‐

alloedmeasprogrammed.

Ifthepowerdropsoutatanymetothepumpthedelaycounterwillbestoppedandwillretainitsvalue,thus

rememberingitsposionwithinthedelaycycle.Thesystemwillthenconnuefromthatpointwhenthepower/

runsignalresumes.

Anindicaonlampislocatedonthemanualoverridebuon,onthebaseofthepump(seebelowimages).The

indicaonlightwillbelitwhenthereisaconnuouspowersupplytothecircuitandpump.Theindicaonlight

willﬂashslowlywhenthemotorisinoperaon.

Pressingthemanualoverridebuon(SeeFig.1B)willoperatethepumpfor1minuteand8seconds(orone‐

completecycle/onecompletecamrevoluon).

ThefollowinginspeconproceduresarerecommendedtohelpensureproperoperaonoftheACchassislubri‐

caonsystem.Oncethereservoirreﬁllperiodhasbeendeterminedmakecertainthattheintervalispartof

scheduledmaintenance.

A. InspectalllubricaonpointsforsignsofFRESHgrease,

B. Checkthecondionofallﬁngsandconnecons.Tightenorreplacelooseordamagedﬁngs.

C. Checkalllubricaonlines;makecertainthattherearenotanybreaks.Checkforwearorchaﬃngthatmay

leadtoleakage.

D. ConﬁrmpumpoperaonbypressingManualOverridebuon(SeeFig.1B)andcheckingtheindicaonlight

ﬂasheslocatedonthebuon.

If,duringthesechecks,anyissuesarefoundusetheLubricaon Troubleshoong Chart onpage14tohelp—

resolvethem.

Fig.1B

AC3OperaonandMaintenance

Operaon

6

Recommended Lubricants

TheACPumphasbeendevelopedspeciﬁcallytorunwithNLGIGrade000,00,0,1and2greaseandFG3,0ﬂuid

grease.OilstoaminimumviscosityofSAE80arealsoacceptable.Donotuseheavytackiﬁedgreasesorgreases

containingbentone/bentonite,molybdenumand/orgraphite.



NOTE: Toensureproperoperaonofthelubricaonsystemonlyeverﬁllwithcleanlubricantthathasbeenina

sealedcontainerandcorrectlystored.Ifcleanlubricantisnotuseditcanresultinprematuresystemorbearing

failures.

Typical Reﬁll Periods

TheAC3reﬁllperiodsrangegreatly,dependingonthenumberofpumpingunits,theoutputquanes,andthe

programmeddelaymes.Duetotheaccuracyofthepumpingunitsoutputquanesandthereliabilityofpump

funconalityreﬁllperiodscanbesimplycalculatedtoensurethatthepumpandthebearingpointsdon’trundry.

Usethefollowingtocalculatereﬁllperiods:



Key:

N=NumberofPumpingUnits(P.U.)witha

parcularoutputvolume.

O1=0.010ccOutput(RedP.U.)

O2=0.015ccOutput(GreenP.U.)

O3=0.025ccOutput(YellowP.U.)

O4=0.040ccOutput(BlueP.U.)

O5=0.060ccOutput(GreyP.U.)

O6=0.100ccOutput(BlackP.U.)

A=TotalOutputAmountper1revoluon

E=NumberofrevoluonsunlEmpty

R1=2,800ccAC3Reservoir

M=1.13=Motorrunmeof1min8secs.

P=Programmeddelayme(3,7,11,15,19,

24,30or36minutes).

AC3

Pumps

Recommended Lubricants

OilsSAE80/90 000Fluid 00SemiFluid 0So 1Sﬀ 2Hard

Minimum

operaon

Temp.

‐40°C/‐40°F ‐35°C/‐31°F ‐30°C/‐22°F ‐25°C/‐13°F ‐20°C/‐4°F ‐15°C/5°F

Maximum

operaon

Temp.

+50°C/122°Fforallpumps*

*(Motorisoperableupto60°C/140°F,butoperangatover50°C/122°Fshortensthelifeofthepump).

Calculaon:

Addupthetotaloutputfromallpumpingunits:

(NxO1)+(NxO2)+(NxO3)+(NxO4)+(NxO5)+(NxO6)=A

Dividethereservoircapacity(R1orR2)bythetotaloutput(A):



R1orR2=E

A

Mulplythenumberofrevsunlempty(E)bythepro‐

grammeddelayme(P),plustherunme(M):

Ex(P+M)=TotalRunmeinminutes(T)

T/60=TotalRunmeinhours(H)

H/24=TotalRunmeindays

Example:

AnAC3(R1)calibratedwith2RedP.U.(O1),4YellowP.U.(O3)

&6GreyP.U.(O5)programmedfora15minutedelayme:

(2x0.01)+(4x0.025)+(6x0.06)=0.48cc

2800cc/0.48cc=5833.33Revs

5833.33x(15+1.13)=87500minutesunlempty,

19531.25/60=1458.33hoursunlempty,

1458.33/24=60.76daysbetweenreﬁlls.

*Notethatthiscalculaonisbasedonthepumphavingan

uninterruptedpowersupplyandbeinginconnuousoperaon*

AC3OperaonandMaintenance

Pump Reﬁll Procedure

TheAC3Groeneveldmullinepumpsareﬁedwithagreasenippleadaptorasstandard(see‘1’below)forﬁlling

withmosttypesofgreaseuptoandincludingNGLIGrade2.Usingthegreasenippleadaptorforgreaseﬁllavoids

thepossibilityofairentrapmentandairpockets(cavitaon).

Bulkﬁlladaptorsarealsoavailableonspecialrequest.Thesecanbeﬁedasanalternavetothegreasenipplein

addiontothegreasenipple(see‘2’belowright).

IMPORTANT NOTES:

 Ensurethatthegreasenippleorbulkﬁlladaptoriscleanbeforereﬁlling.Placethedustcapbackonthe

greasenippleorbulkﬁlladaptorwhenﬁnished.

 DO NOT OVERFILL THE RESERVOIR. FillonlytotheMAXLevelLabel.

7

Operaon

AC3 System Output

(cc’s/grams per hour)

Timer Seng (Delay Cycle)

1.8rpm

0.9rpm

3min

7min

11min

15min

19min

24min

30min

36min

Red 0.53 0.3 0.15 0.07 0.05 0.04 0.03 0.024 0.019 0.016

Green 0.8 0.44 0.22 0.11 0.07 0.06 0.04 0.036 0.03 0.02

Yellow 1.33 0.74 0.36 0.18 0.12 0.09 0.07 0.06 0.05 0.04

Blue 2.12 1.18 0.58 0.3 0.2 0.15 0.12 0.1 0.08 0.06

Grey 3.19 1.77 0.87 0.44 0.3 0.22 0.18 0.14 0.12 0.1

Black 5.31 2.96 1.45 0.74 0.49 0.37 0.3 0.24 0.19 0.16

Injector

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