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.

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

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

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.

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.

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

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.

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

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

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

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.

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