GUDEL Memolub PLCD, Service Manual

Page 1: ...SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC Project Order Bill of materials Serial number Year of manufacture SERVICEANLEITUN 9007199348992139_V B1X XXXXXXXX 101XXXXX 2019 ...

Page 2: ...may deviate from the original In the case of special models options or technical changes the scope of deliv ery may differ from the descriptions here Reprinting the instructions in whole or in part requires our permission Subject to change due to technical im provements 9007199348992139_v2 0_EN US ...

Page 3: ...on 2 0 10 07 2019 Entire manual updated New Outputs open and closed Ü 2 11 1 0 25 05 2016 Basic version Table 1 Revision history Revision history SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 3 ...

Page 4: ...Revision history SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 4 ...

Page 5: ...15 3 Commissioning 17 3 1 Connecting PLCD 17 3 2 Programming 18 3 2 1 Signal waveform over time 18 3 2 2 Suggested solution Programming software 19 4 Operation 21 4 1 Setting the lubrication cycle lubrication quantity 21 4 1 1 Lubrication quantity 21 5 Replacing the cartridge 23 6 Lubricants 25 6 1 Lubrication 25 6 2 Lubricant table 26 Table of contents SERVICE MANUAL Automatic lubrication system ...

Page 6: ...7 Malfunctions Troubleshooting 27 Index 33 Table of contents SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 6 ...

Page 7: ... the Safety chapter of the superordinate manual before working with the product It contains important information for your personal safety The chapter must be read and understood by all persons who work on the prod uct in any of the product s phases You are obligated to implement the infor mation and warnings it contains wherever they pertain to the product Safety SERVICE MANUAL Automatic lubricat...

Page 8: ...Safety SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 8 ...

Page 9: ... of the equipped axes automatically The lubricating pinion unit lubricates the rack The wiper and lubrication unit lubricates the guideway A B C E D Fig 2 1 Design of the MEMOLUB automatic lubrication system A Lubricating pinion unit D Progressive distributor B Wiper and lubrication unit E Lubricant dispenser C Lubrication line Design function SERVICE MANUAL Automatic lubrication system Memolub PL...

Page 10: ...mechanical lubricant dispenser The lubrication is centralized and automated The lubricant is con tained in a cartridge With the progressive distributor several points can be lubricated simultaneously 2 3 1 Control For regular lubricant dispensing the lubricant dispenser needs to be con trolled by a PLC To this end a pulse rhythm needs to be sent for every lubri cation cycle by means of a control s...

Page 11: ... Function of the progressive distributor 1 A Left changeover line D Piston B Main line E Ring groove C Right changeover line F Lubricant From the main line the lubricant flows through the right hand ring groove of piston III The changeover line moves piston I to its right hand end position The lubricant displaced by piston I goes through the left changeover line and exits at output 6 Design functi...

Page 12: ... displaced lubricant exits through output 1 I II III Fig 2 5 Function of the progressive distributor 3 After piston II has moved lubricant flows to the left side of piston III and pushes the piston to its right hand end position The displaced lubricant exits through output 2 Design function SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 12 ...

Page 13: ...ubricant exits through output 3 The progressive distributor continues to follow the func tional sequence as described until all outputs have been supplied with lubri cant As long as pressure is generated by the lubricant the entire procedure keeps repeating in the progressive distributor Design function SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 13...

Page 14: ...stributor is normally supplied ex works with the headless set screw fitted 1 3 4 5 6 2 0 2cm3 0 2cm3 Output Output Piston The same conveying volumes are output by the piston at output 1 and output 2 The connecting passage between the two outlets is closed with the headless set screw Headless set screw Connecting passage Fig 2 7 All outputs open the internals of the progressive distributor are show...

Page 15: ...ributor will not work The piston cannot move A missing lubricating film on guide ways and racks leads to damage to the product This results in operational failure 1 3 4 5 6 2 0 cm3 0 cm3 Output closed Output Piston Output 2 is closed The connecting passage between the two outlets is closed with the headless set screw The piston is blocked by the enclosed conveying volume The progressive distributo...

Page 16: ...output 1 Output 2 is closed The connecting passage between the two outlets is open Connecting passage ü Fig 2 8 Output closed the internals of the progressive distributor are shown in simplified form Design function SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 16 ...

Page 17: ...ed by the semiconductor electronics of output boards M BU BN BU BK M12 5p 3 3 4 4 0 V 24 V 1 2 3 4 BK BU BN WM Cable supplied by customer Memolub Current consumption 0 1 0 2 A Cable length 0 2 1 5 m Plug Pin Feedback of encoder 0 V Motor start 24 V DC 0 V Feedback 24 V DC Fig 3 1 Connecting PLCD Commissioning SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN...

Page 18: ... therefore has to react to the second changing edge at the feedback input 25 min 30 min 20 min 15 min 10 min 5 min 10 s 10 s 25 min 30 min 20 min 15 min 10 min 5 min 10 s 25 min 30 min 20 min 15 min 10 min 5 min 10 s 10 s Motor Motor Motor Encoder Encoder Encoder Start Start Start Normal case Fault Fig 3 2 Signal waveform over time Commissioning SERVICE MANUAL Automatic lubrication system Memolub ...

Page 19: ...lag for machine stop Start lubrication cycle Successful no timeout Yes No Reset warning Reset flag for machine stop Set warning message Reset corresponding warning message as soon as OK again No fault 5 s input AND not empty AND lubrication cycle not started No Fig 3 3 Automatic lubrication system flowchart Commissioning SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 900719934899...

Page 20: ...Commissioning SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 20 ...

Page 21: ...e 4 1 Lubrication quantity per pulse at the lubricant dispenser at an output of the progressive distributor The lubrication quantity per output on the progressive distributor is usually equal However closing an output affects the lubrication quantity per output Lubrication quan tity Calculation example The lubrication quantity is increased by increasing the number of pulses sent to the MEMOLUB lub...

Page 22: ...Operation SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 22 ...

Page 23: ...tion quantity Ü Chapter 6 1 2 25 Ü Chapter 6 1 2 25 Table 5 1 Lubricants Guideways racks and pinions Replace the cartridge as described in the MEMOLUB third party documenta tion Replacing the cartridge SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 23 ...

Page 24: ...Replacing the cartridge SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 24 ...

Page 25: ...ive manu facturers The following tables show the specifications of the lubricants Please inform your manufacturer accordingly They will then suggest an alternative from their product range Low tempera tures food grade Observe the application range limits of lubricants according to the safety data sheet 6 1 Lubrication Fig 6 1 Automatic lubrication system Memolub Lubrication ex works Specifica tion...

Page 26: ...ubricant table Lubrication ex works Specifica tion Lubrica tion quantity Location of appli cation Cate gory Castrol Longtime PD 2KP2K 30 in accordance with DIN 51502 Automatic lubrica tion system Memolub grease Mobil Gly goyle 460 NSF no 136467 CLP PG 460 in accor dance with DIN 51502 Automatic lubrica tion system Memolub oil This table does not purport to be exhaustive Table 6 3 Lubricant table L...

Page 27: ...lly This can lead to severe or fatal injuries Before working in the danger area Secure vertical axes if equipped against falling Switch off the superordinate main power supply Secure it against being switched on again main switch for the complete system Before switching on the system again make sure that no one is in the dan ger area WARNING Overpressure The automatic lubrication system is pressur...

Page 28: ... automatic lubri cation system Lubrication points are supplied too lit tle or not at all Dosage too small Adjust lubrication cycle If necessary adjust inter mission Lubrication lines do not carry lubricant Pre lubrication dis tributor progres sive distributor de fective Replace pre lubrication dis tributor progressive dis tributor Lubrication lines do not carry lubricant Output closed and the head...

Page 29: ...ive distribu tor are shown in simplified form 14 Fig 2 8 Output closed the internals of the progressive distributor are shown in simplified form 16 Fig 3 1 Connecting PLCD 17 Fig 3 2 Signal waveform over time 18 Fig 3 3 Automatic lubrication system flowchart 19 Fig 4 1 Calculation example Lubrication quantity at the lubricant dispenser 21 Fig 5 1 Replacing cartridge 23 Fig 6 1 Automatic lubricatio...

Page 30: ...Illustrations SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 30 ...

Page 31: ...1 Table 5 1 Lubricants Guideways racks and pinions 23 Table 6 1 Lubricants Automatic lubrication system Memolub 25 Table 6 2 Lubricants Automatic lubrication system Memolub 26 Table 6 3 Lubricant table 26 Table 7 1 Malfunctions Troubleshooting 28 List of tables SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 31 ...

Page 32: ...List of tables SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 32 ...

Page 33: ... cycle 21 Lubrication quantity 21 Calculation example 21 M Malfunctions 27 O Output Closed 15 Open 14 P Position of the encoder 10 Programming 18 Software Automatic lubrication system 19 Progressive distributor Function 11 R Replacing Cartridge 23 S Signal waveform 18 Software Programming Automatic lubrica tion system 19 Index SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 900719...

Page 34: ...Index SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US 34 ...

Page 35: ...trie Nord CH 4900 Langenthal Switzerland Phone 41 62 916 91 91 Fax 41 62 916 91 50 E mail info ch gudel com www gudel com chrgal 2 0 10 07 2019 SERVICE MANUAL Automatic lubrication system Memolub PLCD 24 V DC 9007199348992139_v2 0_EN US ...

Page 36: ...GÜDEL AG Industrie Nord CH 4900 Langenthal Switzerland Phone 41 62 916 91 91 info ch gudel com www gudel com ...