Hornche corporation Easylube User manual

RFID Patrol Management

Automatic Lubrication System

Quick Setup

USER MANUAL

For V1.0 Trial Version

January 2011 rev.

Easylube and Guardwatch trademarks are registered by Hornche Corporation.

The content in this document is subject to change without notice. This document is not to be reproduced, transmitted or disclosed to others for any

purpose without written permission from Hornche Corporation.

LSC Lubrication

Specialists

Corp.

612 Chestnut St.

Nanaimo, B.C. V9S-2L2

Canada

r[email protected]

www.lubespec.ca

[email protected]

Description

Determining the exact time for relubrication and the actual

lubricant needed for each bearing are 2 principal skills required by

lubrication technicians in maintaining bearings efficiency. Proper

lubrication is a crucial task when bearing is under lubricated

which will cause premature bearing failure, on the other hand,

over-greasing will lead to catastrophic failure to the bearing

(grease churning and overheating) which eventually damage the

motor coils and windings.

Although this is a common lubrication problem, it can be easily

resolved by latest Easylube®RFID micro-computer lubricator. With

Easylube RFID, the exact greasing volume and re-greasing

intervals for each bearing can be easily calculated and managed

by Easylube MQL software. In addition, the Easylube RFID system

can track, monitor and alert user for lubrication-related issues

during routine inspection thus enhances the efficiency and

effectiveness of maintenance practice.

Easylube RFID is user-friendly, very economical and can easily be

installed at any location; especially support equipments are

located in isolated, scattered, dangerous and negligible area.

Creating the RFID identification system helps lubrication

technicians to eliminate potential human errors and improve

employee safety.

As the result, TPM initiative becomes more approachable. By

making this simple change, tracking of larger maintenance issues

can be easily obtained.

Quick Setup

Here are six easy steps to get the process set up.

Upload collected

data to MQL

software

Download an up-to-

data report to PDA

Step 1

Install the synchronization

software

Step 2

Setup inspection routes

for Easylube®RFID

lubricators or RFID tags.

Step 3

Compile each lube point

data to handheld PDA

Step 5

Always maintain an up-to-

date report on handheld

PDA before performing

inspection route for

accuracy purpose.

Step 6

Monitor updated report and

check abnormality at MQL

software.

Step 4

Upload the data to

MQL software with

necessary calculation

and record.

Routine

Patrol Inspection

(Carry out regular replacement)

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

3

Minimum requirements for synchronization and

general use with a PC or NB:

Microsoft Windows XP OS (V1.0 trial version)

Microsoft Outlook 2000 or later

Microsoft Internet Explorer 4.01 SP1 or later

Microsoft Office 2007, 2003, 2000, XP or later

Microsoft ActiveSync 4.5 or later (for PC; included on HP iPAQ

Getting Started CD)

12 to 65 MB hard disk

2 pcs of USB port

CD-ROM/DVD drive

VGA-capable monitor

Keyboard and Mouse

Minimum requirements for RFID Patrol Management

Program and general use with a PC or NB:

Easylube MQL Software with calculation Formula V1.0 or later (for

PC; included on Easylube Patrol Management Kit Getting Started CD)

Easylube Guardwatch Software V1.0 or later (for PDA; included on

Easylube Patrol Management Kit Getting Started CD)

2 pcs of Easylube Smart Lock

Easylube RWD145B-EL RFID reader

Easylube RFID lubricators or RFID microchip tag

Standard Operating Procedure (SOP) of RFID Patrol

Management Program: Page

Step 1. Software install ................................................................... 4

Step 2. Inspection route setup ......................................................... 4

Step 3. Transmit lube point data using PDA ........................................ 5

Step 4. Transfer PDA data to MQL software ........................................ 6

Register Procedure ........................................................... 7

MQL Calculation ................................................................ 8

Step 5. Keep an up-to-data report to PDA .......................................... 9

Routine Inspection Patrol

Step 6. Inspection Route Report ....................................................... 10

Progress Report

Addendum:

zInspection Route chart .................................................... 11

zProgress Report chart «««««««««««««««««««««« 11

zPre-Warning Monitor Center ««««««««««««««««««. 11

Lubricator Installation Guide

Step 1. Preparation/Maintenance ...................................................... 12

Step 2. Position the Press Plate of device ........................................... 12

Step 3. Test Easylube before installation ................................ 12-13

Step 4. Set/Change the Dispense Period ............................................ 13

Step 5. Start the Lubricator .............................................................. 13

Step 6. Installation ...................................................................... 14

Preparation Work

Direct Mounting procedures

Remote Mounting procedures

Addendum:

Table 1. DIP switch setting for Dispense Period ...................... 15

Table 2. Easylube Lubricator Specifications ............................ 16

Table 3. Direct Mounting Accessories ..................................... 17

Table 4. Remote Mounting Accessories «««««««««««««« 17

Table 5. Troubleshooting Chart of Lubricator .......................... 18

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

4

STEP 1 Software install

Ensure that you have installed the synchronization software -

ActiveSync, MQL software and Guardwatch software as following

steps indicated:

nAt first, insert HP iPAQ Getting Started CD into CD-Drive and

then iQVWDOO³ActiveSync´BEFORE connecting your HP iPAQ

to the computer.

pSecond, insert Easylube Getting Started CD into CD-Drive and

then iQVWDOO³MQL Software´WRWKHFRPSXWHU

pFollowing, connect your HP iPAQ to the computer, and follow

the screen instructions of PC & HP iPAQ both, STEP BY STEP

to complete the installation of ³Guardwatch Software´WR

the HP iPAQ.

STEP 2 Inspection route setup

Setup inspection route through install Easylube RFID

lubricators or label RFID microchip tag to the existing

Easylube lubricators.

nPlease follow the attached ³Lubricator

installation guide´(on page 12) to

installed lubricator. In the meantime, set an

initial re-grease period as required for each

Easylube RFID lubricators at specified lube

points.

NOTE: To assist you with determining the

right setting of re-grease period for your

specific application, after lube point data is

uploading to MQL software, use MQL

Calculation formula (a simple computerized

relubrication calculation program) which helps

you decide which period setting is right for

you.

Or

pIf you had existing Easylube 150B, Classic

or Elite lubricators in the plant, all you need

to do is to label the RFID tag on Easylube

OXEULFDWRU¶Vmain body.

An obvious benefit is that no lubrication points will be

missed out and all lubrication related problems will be

attended to promptly regardless of location and

difficulty.

NOTE: If your HP iPAQ disconnected from the computer, change HP

iPAQ connection from “USB to PC”. Reinstall and start again.

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

5

STEP 3 Transmit lube point data using PDA

Collect all lubrication point data to HP iPAQ by taking into

consideration of actual operating environment as following steps:

nTurn on your HP iPAQ, go to START, click ³GuardwatchΠ

Software´to get the program started.

*First time users: go to PROGRAM, click ³RFID Patrol

Manager´to get the program started.

pPlug in Easylube®RWD145B-EL RFID reader into HP iPAQ,

COM1 is plug in will appear on screen.

pClick START button, COM1 opened will appear on screen.

Your HP iPAQ is now ready for data entry.

qSense Easylube®Reader to each

Easylube®RFID tag systematically;

On event if lube point data is not

yet input, the REGISTER

button will appear on screen.

rClick REGISTER button,

Registration table will appear

on screen (Fig.1), fill in lube point

information as required.

NOTE: If relube instruction is not

available on site; please fill in ³´ to

indicate none, after lube point data

uploading into MQL software the

validity data to be supplemented into

calculation table as required.Fig. 1

sNext, click NEXT PAGE button,

Bearing Operating Conditions

table will appear on screen (Fig.2).

Select bearing working conditions

as required.

NOTE: Please provide all of the

information needed to enhance the

effectiveness and efficiency for

inspection routes.

tStep by step collect each lube

point data to HP iPAQ by

considering of actual operating

condition requested.

Fig. 2

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

6

STEP 4 Transfer PDA data to MQL software

Upload the collected information from HP iPAQ to MQL software

and complete all of the information requested.

nBefore running the MQL software, plug-LQ³Smart Lock´into

the USB connector and click Shortcut on the desktop.

NOTE: 7KH04/VRIWZDUHFRPHVZLWK³6PDUW/RFN´NH\V7KH

purpose is to maintain an accuracy of data during updating,

changing and modifying for data protection.

pFor initial setup; click shortcut of MQL Management Software

on screen, go to System ICON (Fig.3) and click User Set Up.

User set up table will appear on screen, follow the instructions

and fill in the blanks as requested including User and Supplier

information.

pConnect your HP iPAQ to the computer, go to System ICON

(Fig.3) and click DB TRANSFER; DATA Transfer processing

table will appear on screen, follow the instructions on the

screen to complete uploading of data.

Fig.3

The SYSTEM ICON (Fig.3) included:

User set up ±for record of User and Supplier information; click

REVISE to modify the original info, and click ENTER

to complete revision.

Backup ±for file backup; Save will appear automatically when

exit the software, asking the file to be backed up.

Restore ±for restore the backed up file; click restore and the

existing file window will appear, select the file and

click open to restore it.

DB Transfer ±for upload the collected data to MQL software of PC

or download an up-to-date report to Guardwatch

Software of PDA.

qNext, go to Installation ICON, and click Registration

(Fig.4).

Fig.4

The INSTALLATION ICON (Fig.4) included:

Registration ±Click each targeted lube point on the table; the

uploading information will appear on screen.

The initial data is transferred from HP iPAQ;

click REVISE to amend the initial data, and

click ENTER to complete revision.

Calculation ±Click Calculation (Fig.4) into MQL calculation

program; or go to Registration click each

targeted lube point on the table (the single

information will appear on screen) and then

click GO button for calculation, revise or

review record.

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

7

Register Procedure:

Follow register procedure to complete all individual data by new

input or amendment.

nClick each targeted lube point on the table; the uploading

information will appear on screen, and click REVISE for filling

new data or amending previous data.

oMake sure that all individual information is validity accordingly

to established data for each lube points.

pClick GO button for MQL calculation.(Refer to page 8)

Fig.5

REMARK:

Usage of MQL calculation, please refer to page 8. After calculation

is completed; the program will retrieve your calculated records for

review, then go back to REGISTRATION page, click REVISE to

amend the initial data, and click ENTER to complete revision.

The description of REGISTRATION content window (Fig.5)

Install region A location where the lubricator is installed.

Install date The date of lubricator is installed.

Serial No. Lubricator serial number.

Application The name of equipment which lubricator is to be

installed to.

Equipment No. Assign number to the equipment.

Grease No. Grease specs number being used by the auto

lubricator.

Initial setting The initial setting is uploading from HP iPAQ

before MQL calculation to put into practice.

Active setting

The active setting will appear automatically

through calculated computation according your

application.

Adjust date The program will retrieve your calculated date

for review.

RFID code The RFID code will be retrieved from HP iPAQ

Operator

Select the operator who is in charge of the

updating.

(from registration member in user set up)

MQL

This MQL provide expert advices on relubrication

volume and interval for best lubrication

procedure.

Grease Feed Rate The grease feed rate and lubricator¶s

recommended setting period (months) will

appear automatically through computer

calculation according to your application.

Setting period

reference

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

8

MQL (Minimum Quantity Lubrication) Calculation

NOTE烉To assist you with determining the right amount of

grease for each specific application, use MQL Calculation

formula, a simple relubrication calculation program will help you

decide which period setting is right for bearing. Make sure that

each bearing data and actual working conditions are given

correctly.

nBase on the given data, MQL software will start conducting

auto calculation on Minimum Quantity Lubrication (MQL) and

lubrication intervals.

oInput bearing data as requested; then select the grease

replenishing way, the MQL program will automatically

calculate the specific bearing¶s Regreasing Volume.

pThen select the bearing type, rotation speed and actual

working condition (Fig.6), the MQL program will automatically

calculate the actual Relubrication Interval.

NOTE: The relube interval will change accordingly to the

options WKDW\RX¶YHPDGH

qLubricator Feed Rate and Setting Period will appear on

screen. When it is confirmed; click RESET at first and

then click ENTER to complete MQL calculation. (The

program will Return to Registration page automatically)

rBack to the Registration page; follow the instruction to

Active Setting, select Operator and make sure all

information provided is correct, click REVISE at first

and then click ENTER to complete data registration.

NOTE:

If any data is rewritten; you have to click RESET or REVISE

at first, and then click ENTER to complete data registration.

REMARK:

As more advanced greases are being developed to overcome harsh

working conditions such as for high temperature, wet or high

vibration, the adjustments of relubrication interval can be alter

according to each bearing operating conditions.

OEM pre-filled grease cartridge is recommended not only guarantees

grease quality and product performance optimization, but also

enables great reduction in grease consumption and overall

maintenance costs. Please consult your local Easylube®agent for

further information.

Fig.6

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

9

STEP 5 Keep an up-to-data report to PDA

To ensure the efficiency and effectiveness for routine inspection,

always maintain an up-to-date report to your HP iPAQ before

performing inspection route.

nBefore performing inspection route, connect your HP iPAQ to

the computer and click SHORTCUT of MQL software on the

desktop.

oGo to System (Fig.7), click DB Transfer button.

Fig.7

pClick DOWNLOAD, the program will automatically complete

the downloading of an up-to-date data to Guardwatch

Software of HP iPAQ.

This RFID system is user-friendly designed for easy

access to data from each lube point through a

pocked-size PDA and track possible problems during

routine inspection patrol.

Routine Inspection Patrol

During a routine inspection patrol,

lubrication technician will only need to

bring along the handheld PDA.

Follow the steps:

nOn a routine inspection patrol, use

Easylube®Reader to touch a mark

on the at main body of lubricator

for scan RFID tag with. The specific

lube point data will appear on

screen (Fig.8).

oMatch all given information with

the actual operating condition.

If information is matched, choice

a name of patrol person and Fig. 8

then click OK button proceed

to next step.

pIf data was not matched, click

Error Report button, the record

table will appear (Fig.9) for you

to write down the abnormality.

IMPORTANT:

If Easylube®RFID lubricator period

setting or grease balance doesn¶t

matched with the current quantitative

data, please validate of those figures

conditioned to active lubricator unit.

Besides keeps a record of the

abnormality as required.

Fig. 9

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

10

STEP 6 Inspection Route Report

NOTE: The conduct of routine inspection and downloading of

RFID data from each lube point is important and must be

accomplished. It enables real-time tracking of bearing conditions

and maintenance issues.

Upload the collected report to MQL software after

inspection patrol.

nAfter inspection patrol, connect your HP iPAQ to the

computer. Go to System, click DB transfer button (Fig.7).

oClick Upload, the program will automatically uploading all

the collected data to MQL software.

pNext, click Progress Report button (Fig.10).

Fig. 10

RECOMMENDATION:

7RDOORZVPRRWKRSHUDWLRQLW¶VDGYLVDEOHWRVHSDUDWH person

in-charge into two groups. Patrol officer will solely in-charge of

downloading of RFID data from each lube point; whereas software

RSHUDWRUZLOOKROG³6PDUW/RFN´NH\VDQG conduct

uploading/downloading the report.

Progress Report:

When data uploading is completed, the data is automatically

transferred to General Record. Therefore, the software operator will

then examine the inspection route report as following steps:

nGo to Progress Report, click General Record (Fig.11) and

check Error Report and Miss Out. If there is no lubricator

missed out and all bearing are in good working condition, the

program will automatically transfer the inspection route report to

Individual Record.

oIf there had any bearing

abnormality occurred, the

program will automatically

list out the abnormality at

Error Reportor

Miss Out.

(Fig.11).

Fig.11

Click Error Report (quantity) ±

The system is already revealed that error units at side; after you

to pick a lubricator serial number, concerning the Abnormal

Statement will to reveal for your proof.

Click Miss Out (quantity) ±

The system is already revealed that Miss Out patrol units at side;

after you to pick a lubricator serial number, it will list out detail

information in which the lube point has been missed out.

* Click ENTER after the reveal.

IMPORTANT:

Patrol officer shall return to the miss out lube points to

complete the unfinished patrol ASAP. Return to Step 6

uploading the miss report to MQL software.

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

11

Inspection Route Procedures

Progress Report Procedures

Pre-Warning Monitor Center

Routine Inspection ±The system will automatically display the data

for all the lubrication locations and provide the checklist of the Balance

of Consumption and Estimated Replenishment Date, which based

on the period setting time of each lubrication condition; under normal

condition, the Grease Warning Light will remain GREEN z.

zSite Search ±Topper column provide site search function. Pull down

the selection and tick Ascending or Descending, the computer will

execute your request for review.

zStatistic Report ±Use the simple sorting by Estimated

Replenishment Date before printing; click PRINT to print out the

Consumption Statistic Report and arrange for procurement tasks.

zInspection Tour Card ±Use the simple sorting by Install Region

before printing; click PRINT to print out the Inspection Tour

Card for routine inspection patrol.

IMPORTANT:

The program will automatically issue Low Grease Level Warning 15

days beforehand, the RED light warning zwill be automatically

indicated and the warning time will be recorded.

With Easylube RFID you can develop a proper lubrication plan and help

you to avoid unplanned machine downtime.

zGet expert advice on best lubrication procedures through calculate

relubrication volume and intervals.

zCreate RFID identification system; ensure each lube point data

matches the actual operating condition.

zEasy manage all lubrication data by checking list and lubrication

performance history.

EasylubeΠRFID guarantees greasing with 100% accountability.

Download

each RFID

lube point

data into PDA

from MQL

system.

Ensure each

lube point data

matches the

actual operating

condition.

Upload the

collected data to

MQL software.

Go to

General

Record to

check

bearing

abnormality

and missed

inspection.

Go to

Pre-Warning

Monitor Center

to check grease

balance and

date of

replacement

Pre-Warning

Monitor Center

gives off warning

light (red) 15 days

before replacement

date.

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

12

Lubricator Installation Guide

IMPORTANT: Please follow below installation guide step-by-step to

assure Easylube operate successfully and kindly refer to the

Troubleshooting Chart if you encounter any problem during operation.

Step 1. Preparation / Maintenance

This lubricator consists of a Prefilled Grease

Cup that is a replacement Grease Cartridge

designed for refilling at the end of the chosen

setting. At first, remove this Prefilled Grease

Cup and battery pack from its system

connection. 

IMPORTANT:

Use only recommended accessories to optimize product performance,

reduce grease consumption, prevent contamination and enjoy quick

return on investment.

Method of do-it-yourself (DIY):

With any purchase of empty grease cup and

refilling kit, please follow the below instructions

to conduct grease refilling on the grease cup.

CAUTION:

Use only recommended grease with a grease gun. Do not attempt to fill

the cup manually as air may trap within grease and causes blockage or

inaccurate feed volume.



Step 2. Position the Press Plate

IMPORTANT: Always follow instructions to replace grease

cartridge during refilling process.

nTurn the Press Plate clockwise until it is seated at the top.

oNext, follow the instruction label; rotate the Press Plate

counterclockwise to the initial working position.

pScrew the Prefilled Grease Cup into the lubricator body and make

sure it is clamp down on the lubricator body. Under normal

circumstances, the Press Plate will contact Red Piston of the cup;

a small amount of grease will be discharge at the outlet.







WARNING:

Fail to contact the Press Plate to Red Piston will cause the

press plate turns freely without pressing the piston and result in

no grease output.

Step 3. Test Easylube before installation

Easylube lubricator is equipped with Self-Test mode in which enables user to

test the lubricator before use.

NOTE: Elite and RFID model lubricator has its auto-test for

confirming the correct installation; therefore if you apply above

two models, please simply follow step 4.

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

13

nRemove the top cover and battery. Set 4 DIP (Dual

Inline Package) switches to ON position using a small

screwdriver or ball pen.

oPut the battery back to initiate START; during TEST

mode, Easylube will automatically rotate and press

the red piston downward every 7 to 8 seconds, a

small amount of grease will be discharged.

IMPORTANT:

If the Red Indicator Light flashes continuously

during operation (dispensing, Test Mode, etc), user

should aware that possible causes may occur:

Feed blockage or excessive pressure within the

bearing.

Grease cup empty.

Battery low.

Please refer to Table 5 Trouble-Shooting Chart.

Step 4. Set/Change the Dispense Period

The lubricator can be set to any of 12 (months)

dispensing periods and each setting will dispense the

accurate amount of grease at the desired time. Please

refer to Table 1.

nFirst, remove the battery pack from the lubricator.

oSet DIP switches to desired dispensing period to

initial ON.

pPut the battery back to initiate START.

qTighten the top cover.

IMPORTANT:

Always remember to remove the battery for at least 15 seconds

(clearing CPU memory setting) whenever dispensing period is

changed.

Step 5. Start the Lubricator

nAfter completing the TEST mode, remove the

battery. Set DIP switches to ON position to the

required dispensing period. (Refer to Table 1).

oPut the battery back into easylube body to initial

start. Tighten the top cove r.

pLED indicator light will auto blink for 5 seconds to

activate grease dispense reading mode.

qWhen LED indicator light goes off, it indicates that

the lubricator is functioning in working mode.

IMPORTANT:

If the Red Indicator Light flashes continuously during any operation

(dispensing, Test Mode, etc), user should aware that possible causes

may occur:

Feed blockage or excessive pressure within the bearing.

Grease cup empty.

Battery low.

Please refer to Table 5 Trouble-Shooting Chart.

Identification

Make remarks on the top cover label:

Dispensing period

Date of installation

Lubricant used

NOTE: Please use pencil for easy rewritten purpose.

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

14

Step 6. Installation

PREPARATION WORK

IMPORTANT:

Make sure that the existing lubricant in

bearing is compatible with the grease in

the pre-filled grease cup.

nBefore installation, feed fresh grease into bearing until the old grease

was completely removed.

oThis purging process must be operated slowly at low pressure with a

grease gun. Observe where the old grease exists from the bearing?

Press harder on grease gun only when purging process is blocked.

Direct Mounting

CAUTION:

Use mounting bracket only on working condition as bellow stated:

Ambient temperature exceeds 140°F (60°C).

Grease nipple¶s thread is 6mm, 1/16" or less.

Difficult to access area during grease refilling.

nClean grease nipple, then remove it from bearing

housing.

oRefer to Table 3 to select thread type.

pApply seal tape at all connectors during installation.

Connect the adapter to bearing housing with tool,

then lock the lubricator.

qCover the lubricator with provided protection casing.

Remote Mounting

CAUTION:

Do not install the lubricator at ambient

temperature is exceeding 140°F (60°C) or 15

feet (4.6 m) away from the lubrication point.

Keep the tube length and bends to the

minimum.

P-405F mounting bracket and PU tube are suitable for most application.

But if the bearing surface temperature is exceeding 122°F (50°C), then

P-406F and copper pipe are needed.

nInstall the mounting bracket firmly to a

appropriate site.

P-506C + P-405F or P-406F

oClean grease nipple, then remove it from

bearing housing. Select thread type (Table 3).

pApply seal tape at all connectors. Connect tube

to bearing housing with tool, then connect the

tube from the bearing housing to mounting

bracket.

qFeed fresh grease from tube into bearing.

rLock the lubricator at the mounting bracket.

sCover the lubricator with provided protection

casing.

Easylube® RFID lubricator guarantees

greasing with 100% accountability.

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

15

Table 1. DIP switch setting for Dispense Period

MQL calculation ±

Performing the right dispensing of grease and re-greasing intervals at

each bearing are the 2 main keys to maintaining bearing efficiency.

Therefore, please apply minimum volume to lubrication (MQL) by

strictly formula that calculate each bearing requirement. If the

machine comes with OEM lubrication recommendation, follow the OEM

guideline, then take further steps to set actual bearing operating

conditions.

Dispense Period Setting ±

The Pre-Warning Monitor Center of MQL software will conduct precise

calculation on grease consumption and the refilling date for each

lubricator.

NOTE: Please follow dispense period setting strictly for

each bearing based on MQL requirement to optimize

bearing performance.

Dispense

Period

Setting

(Month)

DIP Switch

Levers On

Period Span

Between

Dispense

Cycles

(Hrs)

Amount/Cycle

ml (oz)

Amount/Day

ml (oz)

Amount/Week

ml (oz)

Amount/Month

ml (oz)

150 250 150 250 150 250 150 250

1 1 2

0.417 ml

(0.015 oz)

0.694 ml

(0.024 oz)

5.00

(0.176)

8.33

(0.293)

35.00

(1.232)

58.33

(2.054)

150.00

(5.282)

250.00

(8.803)

2 2 4

2.50

(0.088)

4.16

(0.147)

17.50

(0.616)

29.16

(1.027)

75.00

(2.641)

125.00

(4.401)

3 1 and 2 6

1.67

(0.059)

2.77

(0.098)

11.67

(0.411)

19.44

(0.685)

50.00

(1.761)

83.33

(2.934)

4 4 8

1.25

(0.044)

2.08

(0.073)

8.75

(0.308)

14.58

(0.513)

37.50

(1.320)

62.50

(2.201)

5 1 and 4 10

1.00

(0.035)

1.66

(0.059)

7.00

(0.247)

11.66

(0.411)

30.00

(1.056)

50.00

(1.761)

6 2 and 4 12

0.83

(0.029)

1.38

(0.049)

5.83

(0.205)

9.72

(0.342)

25.00

(0.880)

41.66

(1.467)

7 1 and 2 and 4 14 0.71

(0.025)

1.19

(0.042)

5.00

(0.176)

8.33

(0.293)

21.43

(0.755)

35.71

(1.257)

8 8 16

0.63

(0.022)

1.04

(0.037)

4.38

(0.154)

7.29

(0.257)

18.75

(0.660)

31.25

(1.100)

9 1 and 8 18

0.56

(0.020)

0.92

(0.032)

3.89

(0.137)

6.48

(0.228)

16.67

(0.587)

27.77

(0.978)

10 2 and 8 20 0.50

(0.018)

0.83

(0.029)

3.50

(0.123)

5.83

(0.205)

15.00

(0.528)

25.00

(0.880)

11 1 and 2 and 8 22

0.45

(0.016)

0.75

(0.026)

3.18

(0.112)

5.30

(0.187)

13.64

(0.480)

22.72

(0.800)

12 4 and 8 24

0.42

(0.015)

0.69

(0.024)

2.92

(0.103)

4.86

(0.171)

12.50

(0.440)

20.83

(0.733)

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

16

Table 2. Easylube Lubricator Specifications

Certificate # DEMKO 11 ATEX 1009108X for use in Class I, Zone 2, Ex nA nL IIB T5.

IMPORTANT:

Low temperature Limitation ±this is the lowest temperature

at which the lubricator (motor) in operation. Other factors which

may need to take into consideration are grease viscosity, grease

operating temperature, especially grease pumpability.

Warning:

Please comply with the local environmental protection laws to recycle or

dispose the replacements (grease cup or battery case). Do not burn or

puncture the battery as toxic vapors could be released and caused injury

and environmental pollution.

Replacement Usage ±

zTo guarantee product performance, grease cup and battery are required

to be replaced at every end of dispensing period. When RED indicator

light flashes, maintenance technician has to check immediately

whether it is feed blockage, grease empty or battery low.

zUse only recommended accessories to optimize product performance,

reduce grease consumptions, prevent contamination and enjoy quick

return on investment.

IMPORTANT:

If you encounter any problem during operation, refer to Table 5

Troubleshooting Chart to solve problems.

Lubricator

Model

UL

Approved in

hazardous

location

Material

Outlet Capacity Dispense

Period Setting

Operating

Temperature

Range

Operating

Pressure

Range

Dimensions

(Stature x

Diameter)

Electrical

Ratings

Replaceable

Grease

Cartridge

CE

Certificate

150 Classic

150 Elite

150 RFID

Class I

Division 2

Group B, C, D

Class II

Division 2

Group F, G

Certificate #

E218441

1/2 " PT

(m)

150 ml (c.c.)

(5.28 oz) Adjustable

;

1 to 12 months

(see Table 1)

With Patented

Pre-Warning

System and

LED indicator

-20 to 60° C

(-4 to 140° F)

75 - 150 psi

(5 - 10 bar)

Self-Adjustable

on balance

output pressure

within the

pipeline

15.2 x 8.9 cm

(6 x 3.5") P-613B

Lithium

Battery Pack

6 Volt

CR-P2

2218

Versatility

1000

SHC synthetic

8318

FDA grade

or

DIY filled

with grease

your choice

EC Council

Directive

2004/180/

EC

TÜV

registration

No. AE

50169543

0001

250 Elite

250 RFID

250 ml (c.c.)

(8.80 oz)

19 x 10.25 cm

(7.48 x 4.04")

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

17

Table 3. Accessories for Direct Mounting

(M)烉Male Thread Joint (F)烉Female Thread Joint

Oil Lubrication Guideline

For oil lubrication, the lubricator must be located right below the lubrication

point level. Or, use oil throttle or check valve at grease cup output to prevent

oil leakage.

Table 4. Accessories for Remote Mounting

PU Tube - Normal condition

Part No. Description Part No. Description

P-403S Straight Adapter

1/2"(F) x 3/8"(M) P-403A 45° angle Adapter

1/2"(F) x 3/8"(M)

P-402S Straight Adapter

1/2"(F) x 1/4"(M) P-402A 45° angle Adapter

1/2"(F) x 1/4"(M)

P-401S Straight Adapter

1/2"(F) x 1/8"(M) P-401A 45° angle Adapter

1/2"(F) x 1/8"(M)

P-410S Straight Adapter

1/2"(F) x 10 mm(M) P-410A 45° angle Adapter

1/2"(F) x 10 mm(M)

P-408S Straight Adapter

1/2"(F) x 8 mm(M) P-408A 45° angle Adapter

1/2"(F) x 8 mm(M)

Connectors

MM-111 Extendable pole

1/8"(M/M) x 29mm L FF-101 Straight Connector

1/8"(F/F)

MM-121 Extendable pole

1/8"(M/M), 58mm L FF-191 90° angle Connector

1/8"(F/F)

MM-131 Extendable pole

1/8"(M/M), 89mm L

P-506C Mounting Clip

P-508U PU Tube, 

5 x 8 mm

100 meters per roll

P-405F Mounting Bracket

P-502U Straight Connector

1/4"(M) P-592U 90° angle Connector

1/4"(M)

P-501U Straight Connector

1/8"(M) P-591U 90° angle Connector

1/8"(M)

P-500U Straight Connector

1/16"(M) P-590U 90° angle Connector

1/16"(M)

P-108S Straight Adapter

1/8"(F) x 8 mm(M) P-208A 45° angle Adapter

1/4"(F) x 8 mm(M)

P-106S Straight Adapter

1/8"(F) x 6 mm(M) P-106A 45° angle Adapter

1/8"(F) x 6 mm(M)

Copper Pipe - High Temp. condition

P-506C Mounting Clip

P-608H Copper Pipe, 

6 x 0.8 mm

50 meters per roll

P-406F Mounting Bracket

P-603H Straight Connector

3/8"(M) P-693H 90° angle Connector

3/8"(M)

P-602H Straight Connector

1/4"(M) P-692H 90° angle Connector

1/4"(M)

P-601H Straight Connector

1/8"(M) P-691H 90° angle Connector

1/8"(M)

P-108S Straight Adapter

1/8"(F) x 8 mm(M) P-201A 45° angle Adapter

1/4"(F) x 1/8"(M)

P-106S Straight Adapter

1/8"(F) x 6 mm(M) P-208A 45° angle Adapter

1/4"(F) x 8 mm(M)

Information in this document is subject to change without notice and is not to be reproduced, transmitted or disclosed to others for any purpose without express written permission from Hornche Corporation.

18

Table 5. Troubleshooting Chart



Indications

Possible

Problems Solution

Red indicator

light flashes

zIncorrect

Operation

zGrease Cup

empty

zFeed blockage,

back pressure

exceeds 75 psi

(5.2 bar) or tube

is not completely

purged

zGrease get

harden, thin off

or oil separation

zBattery low

zRefer to instructions of Lubricator

Installation Guide step by step, and

refer to the STEP 3 test the

lubricator before use.

zReplace new battery and pre-filled

grease cup.

zPurge the bearing and tube slowly

with a grease gun until blockage is

released. Make sure that the old

grease is completely purged out

from bearing housing.

zUse test apparatus to measure back

pressure. Keep lube length and

bends to the minimum.

zSwitch to Easylube recommended

grease.

zFollow MQL calculation to set

dispense period.

zNew battery must be used with

each replacement of pre-filled

grease cup.

Indications Possible

Problems Solution

Lubricator

does not

dispense

zBattery low

zPress plate is

not correctly

positioned

zIncorrect type of

grease.

zIncorrect

settings

zWarning light consumes battery;

Verify battery output voltage, it

should exceed 6.0V.

zDo not use battery repeatedly.

zRefer to the STEP 2; Check press

plate position and make sure that it

is in contact with the red piston at

the grease cup.

zTest the lubricator before use.

zUse only Easylube recommended

grease.

zReset dispensing period and

conduct TEST mode.

Quality Assurance and 100% Customer Protection

HORNCHE Corporation provides Two-Year warranty (from the date of delivery)

to all Easylube users that purchased IURP+251&+(¶VDXWKRULzed distributors.

This product is fully supported by +251&+(¶s International Service Centre.

During warranty period, any defective unit will be replaced at +251&+(¶V

authorized distributors.

Please contact [email protected] for more information.

Manufacturer:

HORNCHE CORPORATION Taiwan

HORNCHE CORPORATION Easylube User manual

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