VP PBA Series User manual

VARNA Products
PBA Series Prelube Controls
Simple, Compact, Industrial
Full featured control for running
prelube from the control or from a
remote station
Easy internal wiring connections
Compact NEMA 12 enclosure
Professionally engineered for
safety, including a lock out switch and
fully protected control and
power circuits
VARNA Products
4305 Business Dr.
Cameron Park, CA 95682, USA
www.VarnaProducts.com
1 [phone]
[phone] (International)
Printed in USA 9/26/13 © 2008 VARNA Products
Engineered | Innovation
Feature and Specifications Comparison PBA3208 PBA3240 PBA3480 PBA1208 PBA1240
Operating voltage 208VAC 240VAC 480VAC 208VAC 240VAC
Phases 3 3 3 1 1
Pump Power rating
Motor Protection
Low Power Remote Control Circut
Included
Integrated
1.5 Hp

Printed in USA 9/26/13 © 2008 VARNA Products
General
The VARNA Prelube Control Unit provides all the functions for the operation of the VARNA
CF15 engine prelube pump. The front of the control has a LED illuminated push button. Optional
matching remote push buttons are also available. User supplied buttons and indicator lights may
also be used for remote stations to match the aesthetic of existing control panels. Control
function is identical from any of the control points. Holding any of the buttons generates the
‘Prelube Run’ signal. As long as the signal is present, the prelube pump will run. The ‘Prelube
Complete’ signal can come from an optional pressure switch add-on or another existing signal
from the ECU or other monitoring sensors. Once the ‘Prelube Complete’ signal is received, the
LEDs at all stations illuminate to inform the operator that the prelube cycle is complete and the
engine is ready to start. In addition, the ‘Prelube Run’ and ‘Prelube Complete’ signals may be
connected to various engine control devices for semi-automatic or fully-automatic prelube
control.
Control unit installation is quick and easy with all control side electrical connections on a single
DIN rail for easy accessibility. Four cord grips are provided to simplify sealed cable entry into the
control enclosure. Conduit can also be used in place of the cord grips.
The prelube control unit is self-contained with a power disconnect / Lockout switch, a contactor
for prelube pump motor operation, and a motor protection circuit to protect against phase failure,
motor overload, and short circuits.
VARNA can provide preterminated, labeled cables, to your specified length, for both the two-
conductor engine oil pressure switch, and four-conductor runs to external prelube control signals
or pushbutton stations.
Low voltage control circuit components are protected by circuit breakers located within the
prelube control cabinet so that no spare fuses need to be carried.
Motor Protection
Each model includes the appropriate motor protection for prelube pumps of a matching voltage.
All versions provide 1.5 Hp protection suitable for the VARNA CF-15 pumps.
Application Engineering
It is challenging to address every possible installation type. We are always happy to help in
choosing an appropriate installation setup. Give us a call for engineering assistance and support.
888-676-7774
Engineer’s Corner
VARNA Products PBA Series Controls

Printed in USA 9/26/13 © 2008 VARNA Products
SAFETY WARNINGS and CAUTIONS
WARNING High voltages in and around this equipment can cause serious or fatal injury.
Installation, maintenance, or repair should be done by qualified personnel. Improper use of this
equipment can cause serious or fatal injury.
WARNING This equipment operates high voltage. Only qualified personnel should install or
maintain this equipment. Before working on this equipment make sure that ALL power to this
equipment has been disconnected and that no other sources of power exist that may create an
electrical shock hazard within this equipment. Electric shock can cause serious or fatal injury.
WARNING Only qualified personnel should install or maintain this equipment. This equipment
uses both high voltage power and low voltage control. Note that the high and low voltage
systems are isolated from each other. Crossing or other misuse of these systems can create
serious electrical shock hazards in remote locations outside of this equipment. Electric shock
can cause serious or fatal injury.
WARNING The prelube pump can be remotely operated at any time accidentally or purposely.
Always insure that all means of energizing this equipment have been locked out or otherwise
disabled during installation and maintenance of the prelube pump. Unexpected prelube pump
operation during installation and maintenance can cause electrical shock hazards, contact with,
or entanglement in moving or rotating parts resulting in serious or fatal injuries.
CAUTION The prelube pump can be remotely operated at any time accidentally or purposely.
Make sure that all means of energizing the prelube pump are locked out or otherwise disabled
before changing oil filters, disconnecting the associated oil lines, or maintaining any other
equipment that may cause oil spillage by unintended prelube pump operation.
CAUTION Maximum vibration in the 10 to 55 Hz. range is 1 g RMS. Excessive vibration can
damage the control box. The control box must be mounted in locations that do not receive direct
vibration from the engine or other sources.
CAUTION Completely install the prelube pump and hoses to the engine prior to connecting
power to the motor.
CAUTION The source panel must provide suitable circuit protection to protect the cable
between the source panel and the Prelube Control Unit.
Safety
VARNA Products PBA Series Controls

Prelube Control Unit Installation
1. Locate the Prelube Control Unit in an appropriate location for electrical equipment associated
with the engine. There are cable grips installed for the power cable from the power source to
the Control Unit and for the motor cable from the Control Unit to the Prelube Pump Motor.
For mounting dimensions, see drawing.
2. Install the two power cables to and from the Prelube Control Unit.
a. The minimum conductor size for these power cables is 16 AWG (1.5mm2). Note that
larger conductor sizes may be dictated by the length of the run, by the circuit protection
device in the source power panel, by specific codes, or by standard practice.
b. Connect a four conductor power cable from the VAC 3 phase source panel to the blue L1,
L2, L3, & Ground terminals inside the Prelube Control Unit.
c. Connect a second four conductor power cable from the gray T1, T2, T3, & Ground
terminals inside the Prelube Control Unit to the appropriate Prelube Pump motor
terminals.
3. Install the optional preterminated two-conductor prelube oil pressure switch cable from the
Control Unit to the prelube oil pressure switch at the engine or ECU. VARNA P/N 6435-XX
can be supplied as a kit in whatever length is required for the installation.
a. Install the end the cable with the sheath cut back about 5 inches into the right front cord
grip and connect the wires to the two orange connectors as shown in the Figure 1.
b. This cable is routed from the Control Unit to the Prelube Oil Pressure switch. The black
wire is connected to one of the terminals on the Prelube Oil Pressure Switch and the
white wire is connected to the other terminal.
4. Wire remote prelube station(s). VARNA P/N 6436-XX can be supplied as a kit in the length
required for the installation.
a. If a remote prelube station is not to be used, remove the front left cord grip and close the
hole with a suitable plug.
b. Install the end with the cable sheath cut back about 5 inches (125mm) into the right front
cord grip and connect the Red, Green, Black, and White wires to the red, green, black
and white set of connectors also shown in Figure 1.
c. Rout this cable to the location of the remote prelube station. Note: The maximum length
of AWG-16 (1.5mm2) cable from the Control Unit to furthest remote switch is 44 feet
(13.4m). Longer cables may result in insufficient current to operate the contactor in the
Prelube Control Unit.
d. At the remote location, use a switch or relay to contact the White wire in the Control
Cable to the Black wire in the same cable. While the switch or relay is closed, the Prelube
Pump will run. NOTE: The current draw through the switch or relay will be about 400 mA
steady with a 4 Amp inrush. The voltage across the open switch or relay contacts will be
approximately 24 VAC.
e. Connect the Green and Red wires in the Control Cable to a 24 Volt rated pilot lamp.
When the prelube pump is running, the prelube button lamp will indicate that the preset
Installation
VARNA Products PBA Series Controls

Printed in USA 9/26/13 © 2008 VARNA Products
oil pressure has been reached at the prelube pressure switch. This signal may also be
used to energize a 24 VAC relay to signal an automated engine control that the preset
engine prelube oil pressure has been reached.
5. Verify that the Prelube Pump is installed and plumbed according to its installation
instructions.
6. Turn on the power source to the Prelube Control Unit.
7. Turn the Manual Disconnect on the Prelube Control Unit to the ON position.
8. Verify the pump rotation by quickly tapping the RUN PRELUBE button on the Control Unit
and visually checking the rotation of the fan in the motor. The pump motor must rotate
counterclockwise when viewed from the fan end.
9. Verify that there is oil in the engine sump.
10.Push and hold the RUN PRELUBE button on the Control Unit. The prelube pump will run
until the button is released. The lamp will illuminate when the preset engine prelube oil
pressure has been reached at the prelube pressure switch.
The Power wires from the Source
Panel connect to the BLUE
terminals here.
The Remote Prelube Operator
station wires connect to the BLACK,
WHITE, RED, and GREEN
terminals here.
The Power wires to the Prelube
Pump motor connect to the GRAY
terminals here.
The Prelube Oil Pressure Switch
wires connect to the ORANGE
terminals here.
Figure 1: Wiring the Control Unit

Printed in USA 9/26/13 © 2008 VARNA Products
Operation
Manual Prelube Operation
1. The engine prelube pump can be operated by pushing the prelube button on the control
box. Additionally, the prelube pump can be operated at any of the optional remote prelube
operator stations.
2. The Prelube pump will run while the button is pushed or the black and white wires in the
control cable are connected by a switch or relay.
3. The button lamp will flash while the prelube pump is running.
4. When the preset prelube oil pressure is detected at the engine prelube pressure switch, the
button lamp stays on.
Semi or fully-automatic operation
The VARNA Prelube Control Unit has three external control signals that can be used to operate
the prelube pump and report the state of the engine prelube pressure switch.
1. Prelube Run - It is an input signal to the Prelube Control Unit from a remote switch or a
relay contact closure that is used to run the prelube pump. A contact closure between the
White and Black connector blocks in the Prelube Control Unit will cause the prelube pump
to run. The prelube pump will continue to run until the contact closure opens.
2. Prelube Pressure Reached –It is an input signal to the Control Unit from the engine
Pressure Switch. A contact closure between the two orange connector blocks in the Prelube
Control Unit while the prelube pump is operating will illuminate the button lamp in the control
unit and any connected remote lamps.
3. Prelube Complete - It is an output signal of 24-VAC output signal from the Prelube Control
Unit used to illuminate any connected button lamps. It is on the Red and Green connector
blocks in the Prelube Control Unit. This signal is derived from the Pressure Switch signal.
Operation
VARNA Products PBA Series Controls

Trouble Shooting
1. The button does not illuminate and the Prelube Pump does not run:
a. Check that the circuit breaker to the Prelube Pump Control Unit is on. It might be tripped or turned
off.
b. Check that the disconnect switch on the Prelube Control Unit is on. It might be tripped or turned
off.
i. If the disconnect trips immediately upon pushing the prelube button, verify that each of the 3
phase power lines into to the Prelube Control Unit has power. Also check for broken or shorted
wires leading to the prelube pump motor.
ii. If the disconnect switch trips after 3 or more seconds, check for a jammed pump or failed motor.
c. Check that the low voltage component protection circuit breakers are on. They are located inside
the Prelube Control Unit on the right side. To reset the duel circuit breaker force the blue lever
down into the off position and then back to the on position. The button circuit breaker will pop out
when tripped. To reset it, push the button back in. A miswired Remote Control station or shorted
remote station wires will cause one or both of these circuit breakers to trip.
2. The pump runs but the button lamp does turn on continuously to indicate prelube pressure at
the engine.
a. Verify that there is adequate oil in the engine. Note: Changed oil filters or other maintenance may
require a longer prelube time to purge the filters and oil lines.
b. Check if maintenance has been performed that would allow air in the oil lines to the pump. While
the pump will self prime, it may take some time.
c. Check if the engine is hot and therefore the oil is thin. Oil may be present in the engine but thin oil
could be flowing through the bearings and other oil paths faster than the prelube pump can supply
it. Oil is flowing through the engine but it does not produce enough pressure to operate the
prelube pressure switch.
d. Check for a failed button lamp.
e. Check for breaks or disconnects in the wires to the prelube oil pressure switch.
f. Check for leaks in the Prelube Pump suction line and fittings. These leaks are hard to find. A
relatively small suction leak can keep the pump from priming.
g. Check for proper prelube pressure switch setting.
h. Check that the prelube oil pressure switch is functioning properly.
3. The button light turns on immediately when the button is pushed (no delay while the engine
is filling with oil).
a. Check if the engine is running and therefore oil pressure is already present.
b. Check for shorts in the wiring to the prelube oil pressure switch.
c. Check that the prelube oil pressure switch is functioning properly.
d. Check for proper prelube pressure switch setting.
4. The prelube pump runs whenever power is applied to the control unit.
a. Check for shorted wire(s) to the remote prelube station.
b. Check for shorted or miswired remote prelube cable at the Control Unit or at the remote prelube
station.
Trouble Shooting
VARNA Products PBA Series Controls

Printed in USA 9/26/13 © 2008 VARNA Products

Printed in USA 9/26/13 © 2008 VARNA Products