Lincoln ALS Pneumatic Manual

Owner Manual
Lincoln Auto Lubrication System

Pneumatic Operated Type
LINCOLN AUTO LUBRICATION

SINGLE LINE SYSTEM
ON MINING EQUIPMENT
INSTALLED BY
PT. FLUIDCON JAYA
MANUAL BOOK
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SPECIFICATIONS
Pump Model
Air Operated Pump 83513
Ratio 50:1
Max Output pressure 7500 PSI
Pneumatic
Min Air Pressure 30 PSI
Max Air Pressure 150 PSI
Delivery output Cubic Inch per minute 80
Delivery in cubic inches per cycle .55
Air Inlet Port NPT
Material Outlet NPT
Grease
For Container 40kg Tank
Output Pressure Min 124 Bar ( 1800 PSI )
Output Pressure Max 242 Bar ( 3500 PSI )
Output Flow @ 15 cycles/mm 132cm3/min
Output per cycle 8.8cm3/min
Grease Recommendation Min NLGI-2
Electric
Voltage Input 24V DC
Current 1.6 A max
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DESCRIPTION
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G2 Pulse Lubrication Controller

The G2 Pulse Lubrication Controller is specifically designed for use on systems incorporating a
pumps well as a solenoid valve and pressure switch. The unit can be programmed for pause
cycles from 1 second to 50 hours, maximum pump cycle times of 1 to 50 minutes and solenoid
valve times of 1 to 50 seconds.
The systems can run from 10 to 30 volts DC making it suitable for 12 or 24 volt systems. Low level
monitoring is also available as well as an additional output to drive a fault lamp if required.
SET UP MODE
To enter setup mode apply power while holding the button down for 2 seconds. The fault led will
illuminate to indicate that the unit is in Setup Mode.
The first parameter is the Pause Time. This can be from 1 second to 50 hours. The range leds will
indicate the range of the current setting. To determine the exact setting turn the dial until the range
led starts to blink, this indicates that the dial and range leds are pointing to the current setting. To
select a different setting turn the dial until the range leds and the dial indicate the desired setting,
press and hold the button for 2 seconds. The range led will now start to blink indicating the new
setting has been accepted, This step can be repeated if necessary.
To move to the next parameter simply press the button briefly. Note that the position of the dial is
not significant when simply moving to the next parameter.
The next parameter is the Solenoid Cycle Time. This is the seconds of the solenoids on and off
cycles (e.g. if this is set to 1.5 seconds the solenoid will switch at a rate of 1.5 seconds on and 1.5
seconds off). This setting can be from 1 second to 50 seconds and can be changed as with the
Pause Time.
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To move to the next parameter again press the button briefly.
The last parameter is the Pressure Timeout. This is the maximum time the system can take to
build up pressure. If the pressure switch does not close within this time the unit will assume there
is a fault and go into Fault Mode. Valid range for this setting is from 1 minute to 50 minutes.
Change as per Pause Time. This value must be suitably longer than the maximum possible
pressurizing time of the system to ensure no false alarm.
To move past this parameter press the button briefly.
The last stage of Setup Mode is a Test Mode, this is indicated by the Fault led flashing. The level
and pressure leds will indicate if the level or pressure switches are closed. Holding the button
down will drive the solenoid and pump. CAUTION, note that this will continue for as long as the
button is pressed, regardless of whether the pressure switch is closed or not.
To exit Setup Mode remove power.
OPERATING MODE
RUN
During a run cycle the pump is on continuously while the solenoid cycles at the rate
specified in Setup. The dial and range leds can be used to determine how much time has
elapsed. Once the pressure switch contact closes the unit will enter a Pause cycle. If
however, the pressure switch contact has not closed before the Pressure Time out expires,
the unit will enter a Fault Mode. Pressing the button at any point will terminate the Run
cycle and initiate a Pause cycle.
PAUSE
During a pause cycle the pumo and solenoid are off and the unit counts down to zero
starting from the Pause Time specified in Setup. The dial and range leds can be used to
determine how much pause time remains. Once the time counts to zero the unit will
attempt to start a new Run cycle. If the pressure contact is still closed, however, the unit
will enter a Fault mode instead.
Pressing the button will terminate the Pause cycle and start a Run cycle only if the
pressure switch contact is open. If the pressure switch contact is still closed pressing the
button will have no effect. The Pressure led will remain lit so long as the pressure switch
contact is closed.
FAULT
The are three possible fault conditions
1. Reservoir low level indicated by the level led being on. This occurs if the Level switch
contact is closed at any point during a Run cycle after the initial four seconds have
elapsed.
2. Cycle Timeout indicated by the Pressure led being on. This occurs if the pressure
switch contact does not close within the period specified by the Pressure Timeout in
Setup.
3. Pressure Fault indicated by the pressure led blinking. This occurs if the Pressure
Switch contact has not opened before the end of a Pause cycle.
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In fault mode the dial and range leds can be used to determine how long the fault has
existed (up to 50 hours max). Note that pressing the button will terminate the Fault mode
and start a Pause cycle. The unit must go through a complete Run and Pause cycle first
before the fault time will be reset to zero. If another fault occurs first, the fault time will
continue counting from where it left off.
G2 PULSE WIRING
The G2 incorporates a fuse on the negative supply line. This has been done deliberately as most
applications are automotive and the majority of vehicles are positive earthed. This configuration
ensures that any wiring shorts to earth will draw current through the fuse and thus protect the
system. Note that on negative earth systems it is possible to have a short circuit that by passes the
fuse and may cause damage to the unit. It is recommended to incorporate an external 8 Amp fuse
on the positive supply line on installations on negative earth machines. Also be sure to use the
return wiring points provided and do not introduce negative or positive circuits from other points to
attempts to simplify the wiring, doing so would create alternate paths can by pass the fuse in event
of short circuits.
The low level switch and the pressure switch circuit will work off normally open contact as well as
NPN N/O two and three wire proximity switches. If a three wire proximity switch is used take the
proximity supply from the fault lamp positive terminal. If low level monitoring is not needed simply
leave unconnected.
NB : This unit incorporates MOSFET transistor to drive the pump, solenoid and lamp. Excessive
short circuits on these could destroy the MOSFETs before the fuse blows. Take extra precaution
to avoid the possibility of short circuits. Damage to the MOSFETs from short circuits is not covered
by warranty.
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INJECTOR
SL-1 INJECTOR series H
SINGLE AND MANIFOLD TYPE
For Dispensing Fluid Lubricant and Grease
Not to Exceed N.L.G.I.#1 Grade
SPECIFICATIONS
Minimum operating pressure 1,850 PSI

Maximum operating pressure 3,500 PSI
Recommended operating pressure 2,500 PSI
Maximum vent (Recharge) pressure 600 PSI
Lubricant output is adjustable 0.008 cu.in to 0.08 cu.in
Injectors can be mounted in any position and can be used in circuits with SL-32 and/or SL-33
Injectors.
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SYSTEM OPERATION
STAGE 1
The injector piston is in its normal or rest position. The
discharge chamber is filled with lubricant from the
previous cycle. Under the pressure of incoming
lubricant, the slide valve is about to open the passage
leading to the measuring chamber above the injector
piston.
STAGE 2
When the slide valve uncovers the passage, lubricant
is admitted to the measuring chamber above the
injector piston which forces lubricant from the
discharge chamber through the outlet port to bearing.
STAGE 3
As the injector piston completes its stroke, it pushes
the slide valve past the passage, cutting off further
admission of lubricant to the passage and measuring
chamber. The measuring injector piston and slide
valve remain in this position until lubricant pressure in
the supply line is vented (relieved at the pump).
STAGE 4
After venting, the injector spring expands, causing the
slide valve to move, so that the passage and discharge
chamber are connected by a valve port. Further
expansion of the spring causes the piston to move
upward, forcing the lubricant in the measuring
chamber through the passage and valve port to refill
the discharge chamber.
Injector is now ready for next cycle.
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Adjustments and Priming
Initial Priming of Lubricant Supply Lines (After Installation)

A Remove plug from tee or injector manifold
closest to the pump
B Start pump operation
C When lubricant begins to flow freely from Tee
or injector manifold opening, stop pump
operation and replace plug
D Follow same procedure for Tee or injector
manifold on the next shortest supply line, or
branch supply line
E Follow same procedure for remaining supply
lines and the branch lines, progressively
working to the last and longest supply line run
After all air is expelled and all plugs replaced the pump will build up lubricant pressure and
complete its operation cycle
To prime feed lines
Use a manual or power operated grease gun to prime the feed line.
NOTE : The same lubricant used in the centromatic system must be used in the grease gun.
A Remove filter fitting cap

B Contact injector filler fitting with the grease gun
nozzle. Pump lubricant through the injector and feed
line until there is evidence if lubricant flow at the
bearing
C Replace filler fitting cap. Repeat procedure for each
injector in the system
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System Operation
The system operates as follows :
1. With the pump and timer in rest state, a pause time occurs as determined by the system
lubrication requirements.
2. On completion of the pause time, it will begin a lube cycle. The air solenoid is energized to
deliver air to pump and air to vent valve. Pump begins dispensing lubricant through injector to
the bearings.
3. When all bearings have received lubricant, pressure rises in the system :
For systems with the pressure switch grease pressure will rise until the pressure switch
setting is reached 172 BAR (2500 PSI). The control timer is then reset, de-energizing the air
solenoid valve, cutting air off to the pump and vent valve.
4. Pump stops, grease pressure vents back to tank and the begins (pause time) timing towards
the next lube cycle.
Note :
The 90942 safety Unloader is set to open at 259 293 BAR (3750 4250 PSI) lubrication
pressure. If pressure switch fails to operate and shut off air supply to pump, the safety unloader
will open at approximately 276 BAR (4000 PSI) to relieve lubricant supply line pressure,
(Safety Unloader is preset and cannot be adjusted)
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Sample System Layout on Truck
Sample System Layout on Loader
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Pump Grease Set 03-000888FJ
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TROUBLE SHOOTING
Jika prosedur ini telah diikuti tetapi sistem masih bermasalah, segera hubungi PT. Fluidcon Jaya
terdekat untuk mendapatkan bantuan lebih lanjut.
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FLUIDCON CONTACT ADDRESS:
HEAD OFFICE
JAKARTA SATELITE SUPPORT FACILITIES

Cilandak Commercial Estate
Building 111 M3 - Gunung Bayan Coal Mine
Jl Raya Cilandak KKO, - Drillshop Newmont Sumbawa
Jakarta 12560 - Bengalon KPC Mine Site
Tel :(+62-21)7890550 (hunting) - Bontang PT.Banpu Kitadin
Fax :(+62-21)7890549 Mine Site
E-Mail :jktbrn@fluidcon.co.id
Webpage :www.fluidcon.co.id
OUR BRANCHES
BALIKPAPAN: SUMBAWA:
PT Fluidcon Jaya Concentrator Area Buin Batu
Hidup Baru Industrial Estate Batu Hijau Project Newmont Nusa
Jl.Mulawarman No 21 Rt 023 Rw 007 Tenggara Sumbawa NTB
Manggar -Balikpapan 76116 Ph :(+62 372))635012
East kalimantan Fax :(+62 372))635013
Tel :(+62 542))743389 (hunting) Email :sbwbrn@fluidcon.co.id
Fax :(+62 542))743383 Newmont Extension
Email :bpnbrn@fluidcon.co.id Tel :(+62-21)5799 4600 ext :47364
Email :PT.FluidconJaya@Newmont.com
SAMARINDA:
Jl.Ir. Sutami Blok LL No. 9-10 GOSOWONG:
Kelurahan Karang Asem Gosowong Gold Project
Samarinda 75126 PT.Nusa Halmahera Mineral,Gosowong
East Kalimantan Tel.:(+62-21)788 46967 ext :4793
Tel :(+62-541) 270909 (Hunting) Email :fluidcon@nhm.co.id
Fax :(+62-541) 272625
Email :smdbrn@fluidcon.co.id BANJAR BARU:
Jl.A.Yani Km.33,5
SANGATTA: Banjar Baru -South Kalimantan
Road 9 Area PT.Kaltim Prima Coal Phone :(+62-511)4774843
Swarga Bara,Sangatta 75387 Fax :(+62-511)4777630
Kab.Kutai Timur -East Kalimantan Email :bjmbrn@fluidcon.co.id
Phone :(+62 -549 )21103
Fax :(+62 -549 )21778
E-mail :sgtbrn@fluidcon.co.id
ADARO:
Adaro Site KM7.3
Tanjung
South Kalimantan
Tel/fax :(+62-526)2707774
Email :adarosite@fluidcon.co.id
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Owner Manual

Lincoln Auto Lubrication System

LINCOLN AUTO LUBRICATION

G2 Pulse Lubrication Controller

To move to the next parameter again press the button briefly.

To move past this parameter press the button briefly.

To exit Setup Mode remove power.

Minimum operating pressure 1,850 PSI

Injector is now ready for next cycle.

Adjustments and Priming

Initial Priming of Lubricant Supply Lines (After Installation)

To prime feed lines

A Remove filter fitting cap

The system operates as follows :

Sample System Layout on Truck

Sample System Layout on Loader

Pump Grease Set 03-000888FJ

FLUIDCON CONTACT ADDRESS:

JAKARTA SATELITE SUPPORT FACILITIES

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