MEMOLUB HPS User manual

1509 Rapids Drive
P.O. Box 044051
Racine, WI 53404
Phone: [phone]
Fax: [phone]
www.memolub.com
The
MEMOLUB®HPS
User’s Guide
2.2
PLI, LLC
Power Lube Injection
Represented By:
Revised: November 2005

MEMOLUB®HPS User’s Guide Page 1 of 39 PLI, LLC
TABLE OF CONTENTS
1THE MEMOLUB®HPS ...................................................................................................................................... 3
1.1 OVERVIEW ...................................................................................................................................................... 3
1.2 THE MEMO.................................................................................................................................................... 4
1.2.1 Description............................................................................................................................................. 4
1.2.2 Volumetric Setting of the MEMO ........................................................................................................... 4
1.2.3 Frequency Setting of the MEMO............................................................................................................ 4
1.3 THE LUBRICATOR BODY ................................................................................................................................. 5
1.3.1 Description............................................................................................................................................. 5
1.3.2 Function ................................................................................................................................................. 5
1.4 LUBRICANT CARTRIDGES AND BATTERY PACKS............................................................................................. 6
1.4.1 Lubricant Cartridges.............................................................................................................................. 6
1.4.2 Battery Packs.......................................................................................................................................... 6
1.4.3 Stocking .................................................................................................................................................. 6
1.5 MEMOLUB®EX ........................................................................................................................................... 6
2THE MULTI-POINT LUBRICATION SYSTEM............................................................................................ 7
2.1 FUNCTION ....................................................................................................................................................... 7
2.2 DISTRIBUTION BLOCKS ................................................................................................................................... 7
2.3 COUPLER BRIDGING ELEMENTS ...................................................................................................................... 8
3THE 2-POINT SPLITTER (ALSO KNOWN AS "SPLITTER-MEMO") .................................................... 8
3.1 DESCRIPTION .................................................................................................................................................. 8
3.2 HOW IT WORKS .............................................................................................................................................. 9
3.3 RETROFITTING A MEMOLUB®...................................................................................................................... 9
4THE MEMOLUB®HPS WITH EXTERNAL POWER CONTROL OR SUPPLY ...................................... 9
4.1 THE MEMOLUB®EPC VERSION................................................................................................................... 9
4.2 THE MEMOLUB®EPS: 4.5VDC, 12VDC &24VDC POWERED ................................................................. 10
4.3 THE MEMOLUB®24VDC PLC CONTROLLED VERSION.............................................................................. 11
5ACCESSORIES ................................................................................................................................................. 12
5.1 TUBING ......................................................................................................................................................... 12
5.2 TABLE OF RECOMMENDED PIPE AND TUBING LENGTHS................................................................................ 13
5.3 FITTINGS ....................................................................................................................................................... 13
6INSTALLATION ............................................................................................................................................... 14
6.1 INSTALLING THE MEMO .............................................................................................................................. 14
6.2 OPENING AND CLOSING THE MEMOLUB®HPS .......................................................................................... 14
6.2.1 Opening the MEMOLUB® HPS ................................................................................................................. 14
6.2.2 Closing the MEMOLUB® HPS................................................................................................................... 14
6.3 INSTALLING A GREASE CARTRIDGE .............................................................................................................. 14
6.4 INSTALLING AN OIL CARTRIDGE ................................................................................................................... 16
6.5 TESTING THE MEMOLUB®HPS (CHECK FUNCTION).................................................................................. 16
6.6 MOUNTING THE MEMOLUB®HPS ONTO THE MEMO ................................................................................ 17
6.7 TESTING THE MEMOLUB®HPS (WHILE MOUNTED) .................................................................................. 17
6.8 MAINTENANCE.............................................................................................................................................. 17
7 MOUNTING DO’S AND DON’TS............................................................................................................... 17
7.1 GENERAL ...................................................................................................................................................... 17
7.2 SINGLE-POINT INSTALLATION....................................................................................................................... 17
7.2.1 Direct Installation ................................................................................................................................ 17

7.2.2 Remote Installation .............................................................................................................................. 18
7.3 MOUNTING WITH THE 2-POINT SPLITTER (SPLITTER-MEMO) ..................................................................... 18
7.4 MOUNTING WITH THE PROGRESSIVE DISTRIBUTION BLOCK.......................................................................... 18
8TROUBLESHOOTING .................................................................................................................................... 18
8.1 THE MEMOLUB®HPS DOES NOT WORK ..................................................................................................... 18
8.2 NO LUBRICANT IS COMING OUT OF THE MEMOLUB®HPS .......................................................................... 19
8.3 THE LUBRICANT CARTRIDGE DOES NOT EMPTY CORRECTLY.......................................................................... 19
8.4 LUBRICANT DOES NOT GET TO THE APPLICATION .......................................................................................... 20
9WARRANTY...................................................................................................................................................... 20
APPENDIX................................................................................................................................................................. 21
10.1 MEMOLUB®HPS SPECIFICATIONS ............................................................................................................. 22
10.2 MEMOLUB®HPS DIMENSION DRAWING ................................................................................................... 23
10.3 BASIC PROGRAM SETTINGS........................................................................................................................... 24
10.4 FINE-TUNING YOUR LUBRICATION PROGRAM .............................................................................................. 25
10.5 MULTI-POINT SYSTEM ORDERING INFORMATION ......................................................................................... 26
10.6 MULTI-POINT SYSTEM DISTRIBUTION BLOCK SETUP GUIDE ........................................................................ 28
10.7 2-POINT SPLITTER PROGRAM SETTINGS........................................................................................................ 29
10.8 2-POINT SPLITTER DIMENSIONS .................................................................................................................... 30
10.9 MAINTENANCE ADAPTER INFORMATION....................................................................................................... 31
10.10 INSTALLATION PARTS ................................................................................................................................... 32
10.11 MANUAL LUBRICATION VS.MEMOLUB®AUTOMATIC LUBRICATION ......................................................... 34
10.12 MEMOLUB®EX.......................................................................................................................................... 35
10.13 MEMOLUB®EPC........................................................................................................................................ 36
10.14 MEMOLUB®EPS ........................................................................................................................................ 37
10.15 MEMOLUB®24VDC PLC-CONTROLLED.................................................................................................... 38
10.16 MEMOLUB®24VDC PLC-CONTROLLED INSTALLATION INSTRUCTIONS.................................................... 39
MEMOLUB® HPS has a 2-year limited warranty for replacement due to defects in material and labor. Not
responsible for consequential damages beyond replacement or refund of amount paid. MEMOLUB is a
registered trademark of MEMOLUB International, s.a. © 2003 PLI, LLC.
MEMOLUB®HPS User’s Guide Page 2 of 39 PLI, LLC

MEMOLUB®HPS User’s Guide Page 3 of 39 PLI, LLC
1 The MEMOLUB®HPS
1.1 Overview
The MEMOLUB®HPS is an automatic, self-contained, electro-mechanical lubricator.
The "HPS" in its name stands for High Pressure System. It ejects grease or oil under
programmable control at an output pressure of 350psi. There are three available models:
Cartridge Capacity
Model 120 (Standard) 120cc ¼ pound
Model 240 (Mega) 240cc ½ pound
Model 480 (Giga) 480cc 1 pound
The MEMOLUB®HPS is a highly versatile device of robust design that can be used to
satisfy a variety of application requirements. Its value and reliability have been proven
through years of use by hundreds of companies in thousands of applications.
The MEMOLUB®is a single-point lubricator that can be mounted directly on the
bearing point, slide, gear, or other object requiring lubrication.
The MEMOLUB®can be mounted remotely for safety, ease of service, or
avoidance of hostile environments.
A single MEMOLUB®HPS becomes a 2-point lubricator when used with the
Splitter-MEMO.
The MEMOLUB®can be used as a miniature, low-cost, central lubrication system
to lubricate from 2 to 12 bearings, using a distribution block.
The MEMOLUB®is easily and quickly programmed to eject lubricant at the desired rate
of output and operates as a self-contained lubricator using a battery pack for its source of
power. The EPC (External Power Control) and EPS (External Power Source) versions
expand the application potential of the MEMOLUB®. These versions can be turned on
and off by the machine on which they are being used. This is a valuable feature when
lubrication is required on intermittently or infrequently used equipment. The EPC version
of the MEMOLUB®is battery-powered. The EPS version is powered by an external
source through a power converter.
Under control of a PLC (Programmable Logic Controller) the MEMOLUB®EPC or
MEMOLUB®EPS can be used to lubricate equipment based upon runtime hours,
machine cycles, time of day, or other criteria:
The basic MEMOLUB®HPS is composed of three parts:
The MEMO, which is used to program the rate of lubricant output.
The MEMOLUB®, consisting of a red motor housing and a transparent dome with
spring and locking ring.

The replaceable lubricant cartridge and battery pack.
1.2 The MEMO
1.2.1 Description
The MEMO regulates the rate of grease output of the
MEMOLUB®HPS. It consists of a brass adapter, a black
plastic timing-ring holder, and three plastic timing rings (one
white, one red, and one black). The MEMO is permanently
fitted onto the bearing or other component, and all
MEMOLUB®HPS lubricators of any size will recognize its
program setting.
1.2.2 Volumetric Setting of the MEMO
The brass adapter is an extension of the MEMOLUB's
pump cylinder. One end has a short ¼” NPT thread
used to mount the MEMO on the bearing. The other
end is an M12x1.50 thread that screws into the
MEMOLUB®lubricator. A set of special stroke-
limiting washers is supplied with each MEMOLUB®
for use in programming the volume of lubricant
ejected on each output cycle.
When the MEMO is used without washers (yielding full piston stroke), the output volume
at each stroke is 0.635cc. For each washer inserted into the brass adapter of the MEMO,
the output volume will decrease by 0.04cc per stroke. A Maximum of 8 washers
(including a lock washer) can be inserted into the brass adapter. If the stroke-limiting
washers are used, the lock washer should be inserted last to hold the others in place. If
only one washer is used, use the locking washer. Important Note: When using the 2-Point
Splitter (see Section 3: The 2-Point Splitter), volumetric setting is not possible.
1.2.3 Frequency Setting of the MEMO
The white, red, and black plastic timing rings are used to set
the frequency of ejection cycles of the MEMOLUB®HPS.
They are inserted into the black plastic ring-holder either
individually or in combination to obtain the desired frequency
of output cycles.
MEMOLUB®HPS User’s Guide Page 4 of 39 PLI, LLC

The seven output frequency settings of the MEMOLUB®HPS are as follows:
Ejection Cycle
Rings Used Code Cycles Per Day Frequency
Red, White, & Black RWB 24 1 Hour
Red & White RW 12 2 Hours
Red & Black RB 4 6 Hours
Red R 2 12 Hours
Black & White BW 1.5 16 Hours
White W 1 24 Hours
Black B 0.5 48 Hours
Using the volumetric program settings described in Section 1.2.2 above, and the
frequency settings shown here, it is possible to achieve 52 different rates of lubricant
output. The output settings are shown on two pages in the Appendix titled “Basic
Program Settings” and “Fine Tuning Your Lubrication Program”.
When the MEMOLUB®HPS lubricator is shipped, all three timing rings are seated in the
plastic holder. To remove them, just use a small screwdriver.
1.3 The Lubricator Body
1.3.1 Description
The lubricator body consists of a red motor housing, a transparent
dome, a spring, a compression plate, a black rubber seal, and a black
locking ring. The red motor housing contains all of the electro-
mechanical parts of the MEMOLUB®HPS. The black rubber seal
covers the battery compartment. Because of the configuration of its
grease cartridge, the Model 480 lubricator does not require this black
seal.
The transparent polycarbonate dome protects the lubricant cartridge
and allows for the easy viewing of lubricant remaining. The spring
and the compression plate maintain the position of the lubricant
cartridge on the inlet valve of the pump in the red housing.
1.3.2 Function
An electric motor drives a gearbox. A cam fitted on the outlet
gear drives a lever which lifts the hollow piston and
simultaneously compresses a spring. When the piston reaches
the top of its stroke, the lever is freed from the cam and the
piston begins its downward (working) stroke, driven by the
spring. Lubricant is sucked into the chamber formed above the piston during its
downward ejection stroke, thus preparing the piston for the next cycle.
MEMOLUB®HPS User’s Guide Page 5 of 39 PLI, LLC

1.4 Lubricant Cartridges and Battery Packs
1.4.1 Lubricant Cartridges
Each size lubricator has its own corresponding lubricant cartridge. Every grease cartridge
is filled with care and precision, and is centrifuged during the filling operation to avoid air
pockets in the cartridge that might create an air lock in the pump. Cartridges are not
reusable. The volume of grease in each cartridge is carefully calculated and the weight of
each cartridge depends on the specific weight of the lubricant inside.
PLI, LLC stocks over 250 different greases and oils for filling
lubricant cartridges, but almost any lubricant with a rating of NLGI-
2 or less is suitable for use in the MEMOLUB®HPS.
PLI does not recommend lubricants for a particular application. If a
MEMOLUB®user is uncertain of the type of lubricant to be used
PLI can often assist by providing general information. We can also
assist by referral to the Technical Services Department of the desired
lubricant manufacturer. These Technical Services Departments offer expert advice on the
lubricant requirements for specific applications and the product in their line best suited to
the need.
1.4.2 Battery Packs
A MEMOLUB®Battery Pack is delivered with each MEMOLUB®HPS replacement
cartridge. Each battery pack can empty a lubricant cartridge while operating at
continuous temperatures as low as the following:
STANDARD Model 120 (120cc) cartridge: +21F (-5C)
MEGA Model 240 (240cc) cartridge: +32F (0°C)
GIGA Model 480 (480cc) cartridge: +41°F (+5C)
For continuous operating temperatures lower than those shown, available cold-weather
lithium battery packs should be used.
Battery packs should be changed every time the lubricant cartridge is replaced to assure
proper voltage to the system; and each battery pack should only be used once. A new
battery pack is supplied with each replacement cartridge purchased.
1.4.3 Stocking
Cartridges and battery packs must be stored in cool, dark conditions (preferably in their
original packaging). The shelf-life of stored batteries is 2 years.
1.5 MEMOLUB®EX
The MEMOLUB®EX is the same self-contained, battery powered lubricator as the
MEMOLUB®HPS model with a modified enclosure rated for limited hazardous
locations. This version is identified by the black motor base housing (see Appendix for
EX Ratings).
MEMOLUB®HPS User’s Guide Page 6 of 39 PLI, LLC

2 The Multi-Point Lubrication System
2.1 Function
Using a MEMOLUB®distribution block, the MEMOLUB®
HPS Multi-Point System can service from 2 to 12 lubrication
points. The distribution block is completely sealed to keep out
airborne contaminants, dust, and dirt, and works on the
principal of piston valves. During operation, a series of pistons
inside the block is actuated by the flow of lubricant from the
MEMOLUB®lubricator. Lubricant flows through a series of
internal channels in the distribution block, when one piston
valve is filled the other is emptied through its output port. The pistons move in a
prearranged sequence to allow for the progressive distribution of lubricant to all lubricant
points.
A built-in check function can be used to confirm that the
system is operating properly. An indicator pin is located
on the last piston of the distribution block. The pin
moves back and forth at the completion of a lubrication
cycle. If there is a blockage anywhere in the system, the
system stops lubricating and the indicator pin ceases to
move. Visual inspection of the indicator pin can be used
to verify proper operation of the system.
To remotely and continuously monitor operation of the system a distribution block with
an optional limit switch is available. An electric circuit is attached to the limit switch. The
limit switch is activated by the indicator pin, which makes or breaks contact in the
electrical circuit. This signal may be tied into a monitoring device to display visual or
audible indication of the systems operation.
2.2 Distribution Blocks
On each output cycle of the distribution block each outlet port ejects .3cc’s of lubricant.
Multi-point systems are available using distribution blocks with an even number of outlet
ports (i.e. 4, 6, 8, and 12). Multi-point lubrication systems are designed using these basic
distribution blocks and the coupler bridging elements described in Section 2.3 below. The
coupler bridging elements permit the design of systems with a number of outlet ports
other than those of the basic distribution block.
MEMOLUB® multi-point lubrication systems are generally delivered to the user pre-
assembled with the specified number (2 through 12) of lubricant outlet ports, charged
with the appropriate lubricant and ready to install. Tubing pre-filled with the desired
lubricant is available in various lengths to facilitate installation. These ready-to-use
systems are termed MEMOLUB®Plug 'n LubeSystems. Empty tubing is also available
which the user may charge with lubricant upon installation.
MEMOLUB®HPS User’s Guide Page 7 of 39 PLI, LLC

On occasion it may be desired to retrofit a previously-purchased MEMOLUB® lubricator
into a multi-point system, or change the number of outlet ports in a multi-point system
that was previously installed. When this occurs, individual distribution blocks and coupler
bridging elements are available from PLI.
PLI and its distributors are always available to assist in the design, layout, and ordering of
a multi-point system appropriate for your needs.
2.3 Coupler Bridging Elements
For those applications requiring an odd number of lube points, coupler bridging elements
may be required for linking two outlet ports together. In this case, the lubricant volume at
the outlet of the coupler will be doubled. For instance, an eight-port distribution block
with two outlet ports linked together by a coupler becomes a seven-port distribution block
with one port receiving twice as much lubricant as the other six ports. Cross-porting using
coupler bridging elements can be advantageous when designing systems in which some
bearings on the system require greater amounts of lubricant than others. The use of
couplers for cross-porting outlet ports on distribution blocks is illustrated and further
explained in the Appendix (see “Distribution Block Set-Up Guide”).
3 The 2-Point Splitter (Also known as "Splitter-MEMO")
3.1 Description
The Splitter-MEMO divides the volume of lubricant at each
ejection cycle of the MEMOLUB®HPS. It is specially designed
for the economical lubrication of two-bearing shaft systems such
as electric motors, pumps, and fans. It transforms the
MEMOLUB®HPS into a two-outlet system.
The Splitter-MEMO can be used with any of the three sizes of
MEMOLUB®HPS lubricators (namely the Model 120, Model
240, or Model 480). Refer to the Appendix for Splitter-MEMO
Output Programming.
The Splitter-MEMO replaces the brass fitting of the normal MEMO. The black plastic
timing ring holder and three colored timing rings are used with the Splitter-MEMO to
program the frequency of lubricant ejection cycles. The black plastic timing-ring holder is
fit onto the Splitter-MEMO in the same manner as on the brass fitting of the standard
MEMO. The Splitter-MEMO comes equipped with 5/16” (8mm) push-in tube fittings on
the outlet ports. Important: The Splitter-Memo can only operate under full-piston stroke.
Do not attempt to insert stroke-limiting washers into the Splitter-MEMO.
It is recommended that the Splitter-MEMO be used with greases having a base-oil
viscosity of no more than 10,000cSt, at working temperature. Check with your
MEMOLUB®distributor, lubricant supplier, or with PLI for base-oil viscosity
information.
MEMOLUB®HPS User’s Guide Page 8 of 39 PLI, LLC

The lengths of tubing that can be used with the Splitter-MEMO applications are
determined by the base-oil viscosity at the working temperature of the grease used. The
table in Section 5.2 provides information on recommended maximum tube lengths to be
used with the Splitter-MEMO. Contact your MEMOLUB®distributor, PLI, or your
lubricant supplier for information on the temperature at which the base-oil of the grease
being used reaches this viscosity.
3.2 How It Works
An explanation of the operation of the Splitter-MEMO, with diagrams, is provided in the
Appendix. Also provided in the Appendix are dimensional drawings of the system when
used with each of the three sizes of MEMOLUB®Lubricators.
Caution: Splitter-MEMO’s are carefully pre-filled to 100% capacity at the factory with
the same grease ordered in the MEMOLUB®cartridge. Do not open the Splitter-MEMO
or manually activate the Stem Valve. In both cases air will be introduced into the system.
3.3 Retrofitting a MEMOLUB®
A MEMOLUB®HPS can be retrofit in the field to a 2-
point Splitter-MEMO. Retrofitting is accomplished by
removing the black timing ring holder from the brass
fitting of the MEMO and placing it on the Splitter-
MEMO.
Retrofitting a MEMOLUB®HPS in the field may require
recharging the Splitter-MEMO with the grease being used.
SPLITTER MEMO's purchased without a MEMOLUB®Lubricator have been pre-
charged with lithium-based grease at the factory. If incompatible grease or a special
grease (e.g. food-grade) is to be used, it will be necessary to recharge the Splitter-MEMO.
To do this, use the Zerk grease nipple that is supplied with the Splitter-MEMO to pump
the correct grease through the outlet port labeled #1 (see illustration above). This is the
outlet port closest to the base of the Splitter-MEMO. The Splitter-MEMO must be
recharged without the MEMOLUB®Lubricator mounted on it. Pump grease into outlet
port #1until it seeps through the piston at the top of the Splitter.
4 The MEMOLUB®HPS with External Power Control or Supply
4.1 The MEMOLUB®EPC Version
MEMOLUB®HPS User’s Guide Page 9 of 39 PLI, LLC
The EPC (External Power Control) version of the MEMOLUB®HPS is
ideal for avoiding over-lubrication in applications where machinery is
used infrequently or intermittently. The MEMOLUB®EPC operates
under its own battery power but the lubricator is turned on and off
externally. A 12” lead-wire extending from the base of the lubricator is
connected to a relay. This relay is opened and closed in concert with