Pulsarlube ML500 User manual

Models
PULSARLUBE ML500 (500cc Grease Lubricator)
PULSARLUBE OL500 (500cc Oil Lubricator)
Before Use
Thank you for your purchasing PULSARLUBE M 500cc, the new and unique electro-mechanical single-
point automatic grease dispenser from Pulsarlube USA, Inc. To ensure the safe operation and proper
installation of the PULSARLUBE M 500cc unit, we strongly recommend that you read the following
information carefully before use. If you require further information, please contact your local supplier.
Safety instructions
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
1. Read and save all notices, warnings and safety instructions received with equipment
2. Safety Instruction for Battery
•Store battery at room temperature between 40° and 80° F for best results.
•Do not expose battery pack to direct sunlight (heat) for extended periods.
•When transporting or temporarily storing in a vehicle, temperature range should be greater than
20° F but no more than 150° F.
•Store battery away from other flammable materials.
•Storing battery at temperatures greater than 170° F for extended periods of time (more
than 2 hours) may cause damage to battery and possible fire.
3. Explosive Proof
Don’t use unit whereas explosions endanger the lives and health of workers as a result of the
uncontrolled effects of flame and pressure, the presence of noxious reaction products and
consumption of the oxygen in the ambient air which workers need to breathe.
4. Product Warranty
Product warranty is limited to original defects in material and workmanship. Warranty does not cover
collateral damage. Due Misuse, abuse, incorrect charging and other inappropriate use of this product
are not covered under warranty.

Control Panel
Cross Section View

Buttons
Display FunctionName
Set Dispensing Period
Mode
&
Locking
Select one of the eight different dispensing rates
(1/2, 1, 2, 4, 6, 12, 18 and 24 Month)
The dispensing rate can be changed during operation.
Auto Locking Mode is provided to confirm that the unit MUST
operate as per user setting in full period of service. It prevents a
possible mode change by unintended (or erroneous) pressing
keypad when the unit is still operating. When all modes are
completely set, ML500 unit automatically locks keypad within 60
seconds and a “Lock Icon ( )” will pop-up on LCD.
Once activated, the unit will not accept any input by pressing
keypad. To unlock the keypad and go back to installation mode,
simply press the “mode” button for 2 seconds until Lock Icon
disappears.
Power ON/OFF
Depress the button for 2 seconds
- To turn unit on and off.
- To go stand by mode
Test
The test function is provided to confirm that the unit works prior to
installation or after replacement of service pack.
IMPORTANT:
To activate test mode, depress the button for 2 seconds. “test”
should start blinking and an audible gear mesh sound will confirm
unit operation and a grease discharge should be observed. If the
unit does not operate in Test Mode, it should be returned to your
supplier. To deactivate test mode, depress the test button again.
The unit will then stop functioning in test mode within 20 seconds.
Otherwise, the unit will automatically stop test mode after 2 minutes
and be back to previous mode set.
Reset
Use when service pack is replaced.
Use to reset unit back to its default setting following;
- Abnormal display on LCD screen.
-A unit malfunctions or when the Power ON/OFF button is not
available.
CAUTION!
Depressing reset will eliminate all previous settings and records.

LCD Display-Function
Name Display Function
Dispensing Period
Set
Indicate set period
Day Till
Replacement
Days till replacement-Indicates the remaining days till
replacement (days to expiry)
Daily Dispensing
Rate Indicate daily dispensing rate
Days After
Dispensing
Completion
Days after dispensing completion (Expiry)
St-XX indicates the number of days since the lube cycle has
been completed or the grease pouch has become empty.
 “St” denotes “Stop”
Checking Lube
Line
Days after backpressure sensing
Ch-XX indicates the number of days since the unit stopped
due to lube line backpressure.
(All functions will stop except TEST MODE to protect unit)
Test
Dispensing test mode
Indicates test mode is activated.
Auto Locking
Indicates all system was locked
Battery
Low battery power
Indicates low battery power
Backpressure
Sensing
Capability
Backpressure sensing capability
Check bearing and grease feed line
To clear this signal, just press “Test” Button for 2 second.
Replacement
Service pack
Low grease level
Indicates that the lube cycle has been completed or that the
grease pouch is empty
Cartridge
Capacity Indicate cartridge capacity
Signal Lamp
For Low battery power, Backpressure Sensing, or Low
grease level, the red LED will blink periodically.
Note: LCD may be not clear if battery is lowError!

Install & Replacement
1) ML 500;
A. First Installation
1. Before installation of the Pulsarlube ML, the lubrication point (bearing and
passage) should be manually lubricated using a grease gun to ensure that
the bearing has a clear passage. It is recommended that this procedure be
conducted using either the same or a compatible lubricant with what is
contained in the grease pouch of the Pulsarlube ML.
If any doubts exist in regards to a clear lubrication flow, test the
backpressure of the bearing with a grease gun connected to a pressure
gauge. Ensure that the break – off pressure is below 500 psi (approx. 35
kg-f/cm2: 34.5 bar). Note that it is always desirable to keep the constant
delivery pressure as low as possible.
2. Remove the grease nipple
3. Insert the Battery Pack into the battery compartment of the main unit.
(Make sure that the battery is locked in place after insertion by turning the
metal clip on top)
4. Place the pointed open end of the grease Cartridge over the lubricators’ top
check valve and turn cartridge clockwise until you hear the top housing “click”.
5. To activate/release the spring, remove top “center” cap from top of grease
cartridge. Unscrew wing nut on top of grease cartridge and replace “center”
cap.

6. Install an appropriate adaptor of 3/8” NPT or BSP and make sure that the
unit is well tightened to it. The 3/8” brass thread of the unit is vibration proof.
In other words it ensures that that fitting will not snap off at the nose even
under severe vibration or shock load.
7. Turn the Pulsarlube ML 500cc unit ON by depressing the POWER button
for 2 seconds. To confirm that the LCD is working, make sure that the Red
LED blinks once as soon as you press the “power” button. The unit is working
as long as the LCD displays information.
Then press the TEST button for 2 seconds. The unit will begin to start
dispensing grease. The unit will operate continuously in Purge mode and go
through an entire cycle of (approximately 2 min).
To deactivate the TEST MODE FUNCTION, press the TEST button again.
The unit will stop testing within the next 20 seconds.
Depress the MODE button to set the dispensing rate. Each time the MODE
button is depressed, the dispensing rate changes in ascending order
i.e. 1►2►4►6►12►18►24►H. Note: (H = Half month.)
Note: If you are unable to program a setting and a lock icon is displayed,
press the mode button for 2 seconds until the lock icon disappears.
Program your lubricator. The unit will automatically lock 30 seconds after you
stop pressing any of the 3 programming buttons.
8. Use attached label to note grease type, installed and expiry date.
9. Use dust cover to keep the unit cleaned.

B. Cartridge replacement: Same procedure with first installation 3~9.
1. Replace the Cartridge and Battery Pack from the battery compartment of
the main unit.
(IMPORTANT NOTE)
1) It is highly recommended that you use factory filled gre ase
ill be void if unit malfunctioned cause of customer filled
2) Battery pack has to replace simultaneously with cartridge.
cartridges.
(Warranty w
cartridges)
2. Use attached label to note grease type, installed and expiry date.
3. Use dust cover to keep the unit cleaned.
2. OL 500
A. First Installation
1.In
-between oil being used and plastic that
-It should be more convenient if standard kit will be used.
stall single or multi point remote kit in the proper location.
Check for the compatibility
the lubricator is made of.
t the battery is locked in place after insertion by turning the metal clip
on top)
2.Insert the Battery Pack into the battery compartment of the main unit. (Make
sure tha
3.Put oil absorbent on the top of battery.

4. Assemble oil cartridge with main body (Empty cartridge)
5. Install mounting bracket in the proper location using the screws or bolts. It
is good practice to mount the lubricator in close proximity to the bearing to
keep feed lines as short as possible.
6. Close the cartridge cover after pouring oil.
7. Turn the Pulsarlube OL 500cc unit ON by depressing the POWER button
for 2 seconds. To confirm that the LCD is working, make sure that the Red
LED blinks once as soon as you press the “power” button. The unit is working
as long as the LCD displays information.
Note: If you are unable to program a setting and a lock icon is displayed,
press the mode button for 2 seconds until the lock icon disappears.
Program your lubricator. The unit will automatically lock 30 seconds after you
stop pressing any of the 3 programming buttons.
8.Use attached label to note grease type, installed and expiry date.

9. Use dust cover to keep the unit cleaned.
B. Battery Replacement: Same procedure with first installation 2~9.
1. Turn off cartridge and replace battery pack and oil absorbent.
2. Refill oil and use attached label to note grease type, installed and expiry
date.
3. Use dust cover to keep the unit cleaned.
C. PULSARLUBE OL500 Multipoint lubrication system
1. Oil supplying system: Proportional oil supply system:
Proportional oil supply system flow unit is the pipe connecting parts with built-in controller for the quantity of
refined oil. Distribution flow unit is positioned on the branching joint of distributor, used by attaching a
conduit to the end of it. Also there are five stages from No.0 to No.4 for each type. The gauge of flow is
changed based on the number and the points consist of coefficients of two as the table below for each stage.
Valve No. #0 #1 #2 #3 #4
Flow rate 5 10 20 40 80

2. Distributor for PULSARLUBE OL500
1) Lubrication point: Max 4 points
2) Available oil viscosity: 46 ~ 10,000 cst(40°C)
3) Tube size; Out Dia ø4 (Poly Tube)
4) Oil accessories (Optional)
NOTE) About Proportional Valve;
-The flow gauge of flow unit is determined by the thickness of inner rod, the flow unit has a built-in check
valve for one-sided control so there is no effect under the mutual difference of altitude and distance from
pump, and check valve is supposed to be open when hydraulic pressure is 0.35kg/cm² On the side of each
unit, type No. and flow direction of oil are specifically engraved.
- The dispensing volume will vary upon oil viscosity, environmental temperature and lube point condition.
Dispensing Recommendations
In the chart below are some guidelines for bearing lubrication requirements.
Requirements may vary with individual bearing types or operating conditions.
Bearing Shaft
Dia. 125cc
Grease
Volume
(cc/day)
250cc
Grease
Volume
(cc/day)
500cc Grease Volume
(cc/day)
230 – 330mm
(9” – 13”) N/A - N/A - H Month 33.3
166 – 229mm
(6 1/2” – 9”) N/A - H Month 16.6 1 Month 16.6
102 – 165mm
(4” – 6 1/2”) H Month 8.3 1 Month 8.3 2 Month 8.3
90 – 101mm
(3 1/2” – 4”) 1 Month 4.2 2 Month 4.2 4 Month 4.2
77 – 89mm
(3” – 3 1/2”) 2 Month 2.8 3 Month 2.8 6 Month 2.8
12 Month 1.4
65 – 76mm
(2 1/2” – 3”) 3 Month 1.4 6 Month 1.4
18 Month 0.9
51 – 64mm
(2” – 2 1/2”) 6 Month 0.7 12
Month 0.7 24 Month 0.7
25 – 50mm
(1” -2”) 12 Month 0.3 N/A - N/A 33.3

Lube cycle and dispensing volume
Dispensing
Period (Month) Lube Cycle (Cycles/day) Dispensing Volume
(cc/day) Display on LCD
½ 15 min (96) 33.3
1 30 min (48) 16.6
2 1 hour (24) 8.3
4 2 hours (12) 4.2
6 3 hours (8) 2.8
12 6 hours (4) 1.4
18 9 hours (2.66) 0.9
24 12 hours (2) 0.7
TEST Continuous (-) 16.6
Pulsarlube ML 500 cc unit Battery Selection Guide
Backpressure
Item
Type Temperature Range ML 500 OL 500
Standard
(Alkaline Battery)
14°F~122°F
(-10°C~+50°C)
*280psi (20kgf/) or less
Constant Back Pressure
*Under 280psi (20kgf/)
*Multi Point
Option
(Lithium Battery)
-40°F~140°F
(-40°C~+60°C)
*Over 280psi (20kgf/)
*Use Divider Block (Multipoint)
*Setting 24 Months
N/A
- Battery should be replaced when grease cartridge will replace and oil refill

Pulsarlube ML500 / OL500 Troubleshooting Guideline
Trouble Cause Remedy
LCD Screen
displays fault or red
light blinking or
black screen .
- Possible electrical malfunction of
CPU or circuit.
- Battery pack missing, faulty or
incorrectly installed.
- Old battery pack was not replaced
during changeover.
- Battery leakage occurred
-Have to use manufacturer’s standard
battery.
- The battery pack must be replaced with
each changeover.
- Store battery pack in a cool and dry
place prevent impact damage
Low battery
indication
- Battery pack expired (Low Battery)
- An unusual storage condition may be
encountered(Temperature& humidity)
-Damaged battery pack
- Extreme environment
-Change battery pack.
-Should be installed under condition of
280psi(20kgf/) backpressure area.
- In case of high temp, over
280psi(20kgf/) backpressure area,
recommend to use Lithium battery.
TEST METHOD
↓Unlock
↓
Press Mode Button for 2 seconds
Press Test Button for 2 seconds
Backpressure
Sensing Capability
- Over lubrication occurring
- Grease blockage
- Excessive back pressure
-
Extreme operating temperature
- Low battery
-Check backpressure.
-Check grease dispensing rate
-Reduce remote install distance
-Have to use Lithium battery at low
temp environment condition
Need to
check
Reinstall unit

Air pockets must be eliminated from the
grease in the cartridge. This is reason why
It is highly recommended that you use
factory filled grease cartridges.
Unit won’t dispense
grease
Deaeration
Air or Oil was trapped in the
pump inlet check valve
Pump will be idling without grease
dispensing if air will be in.
Please push cartridge bottom check valve
by using ø5~ø6 pin till grease comes out
from nozzle.
To eliminate oil & air from the pump
↓
↓
↓
↓
Press Mode button for 2 seconds
to unlock unit
Press Test button for 2 seconds
Press softly pump check valve by
using ø2 pin to eliminate oil and
air from the pump inlet
Repeat again till grease coming out
Assemble cartridge and set mode

Specification
Specification ML 500 OL 500
Capacity 500 cc ←
Power
DC 4.5 Volt (Battery pack)
Standard: Alkaline Battery
Option: Lithium Battery
←
Temperature Standard Battery: 14°F~122°F (-10°C~+50°C)
Lithium Battery: -40°F~140°F (-40°C~+60°C) ←
Working Pressure Under 280 psi (20kgf/) ←
Size Height; 9.5in(240mm) x Diameter; 4in (101mm) ←
Weight 1.2 Kg (Included Grease weight) 0.8 Kg
(Not included oil weight)
PT 3/8 in ←
Nozzle size
Dispensing 1/2, 1, 2, 4, 6, 12, 18, 24 Months (8 different mode) ←
Period
Up to 8 points Up to 4 points
Multi point
Main unit Service pack
←
Package Individual pack Individual pack
1 case (8 units) 1 case (10 units)
Remark; Manufacturer is subject to change without prior notice.
Warranty
Pulsarlube USA, Inc. guarantees the product to be free of defects in material and workmanship for a
period of 12 months from date of delivery. Warranty is limited to replacement of the product. There is no
consequential loss covered by the Warranty. The Warranty will be void if the unit is mistreated, tampered
with, used in a hostile chemical environment, used under water, maliciously damaged, used outside the
specified ambient operating temperature range of -15°C~ +60°C (5~140°F), used with other than from a
service pack. Please contact your local supplier or the manufacturer for the validity of the Warranty.
Pulsarlube USA, Inc.
http://www.pulsarlubeusa.com