LUBE EPM Instruction Manual

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EPM (End Point Monitor)

EPM Sensor

Instruction Manual

・ For your safety, carefully read and understand this

instruction manual before starting the work.

・ Always keep this instruction manual in a certain

place so that you can read it whenever necessary.

LUBE

Corporation

L-0424-3E

Table of Contents

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Summary of Contents for LUBE EPM

Page 1 L-0424-3E EPM (End Point Monitor) EPM Sensor Instruction Manual ・ For your safety, carefully read and understand this instruction manual before starting the work. ・ Always keep this instruction manual in a certain place so that you can read it whenever necessary.
Page 2 Introduction ■ Intended use of device The EPM sensor is a device for monitoring the flow of the lubricant fed from each valve of our lubrication system to each lubrication point on the machine body and the temperature change of the machine components.
Page 3 ■ Contact information If you have any questions on this instruction manual, contact the following. ■ Japan Order Reception and Customer Support Center, LUBE Corporation (Located in Tsukuba Plant) 15-1, Okubo, Tsukuba, Ibaraki, 300-2611 TEL: 029-877-5506 FAX: 029-865-3176 ■ China LUBE LUBRICATING SYSTEM (SHANGHAI) CO.,...
Page 4: Table Of Contents
Cleaning Instruction ······························································· 31 Disassembly/cleaning/assembly ·············································· 312 4. Wiring ······················································································· 344 Wiring Between EPM Sensor and Fringe Board Unit ················· 355 Wiring Between Fringe Board Unit and Relay Board Unit ·········· 366 Power Communication Wiring of Relay Board Unit ··················· 377 Alarm Wiring of Relay Board Unit ··········································...
Page 5 Step 3: Dial Code Setting of Fringe Board Unit ································· 544 Step 4: Installation of Fringe Board Unit ·········································· 555 Step 5: Mounting EPM Sensor ························································ 566 Step 6: Wiring of Relay and Fringe Board Units ································ 588 Step 7: Alarm Wire Connection ······················································· 599 Step 8: Pump Operation Signal Wiring ···············································...
Page 6: Safety Precautions
1. Safety Precautions Basic Safety Precautions • Before starting the work, carefully read and fully understand this instruction manual. • Keep this instruction manual in a certain place so that you can read it whenever necessary. • The device can only be operated by personnel with knowledge and technique of installing and adjusting a lubrication system.
Page 7 (1) EPM sensor specification and serial No. (engraved on the body) DC3~24V 5mA MODEL EPM-L-01-W-2.5-C CODE No. 420100 SERIAL No. TE20K0001 DC3~24V 5mA MODEL EPM-L-01-W-2.5-C CODE No. 420100 SERIAL No. TE20K0001 (2) Relay board unit nameplate (3) Relay board unit specification and serial No.
Page 8 ＶＯＬＴＡＧＥ　　　　　　　　ＤＣ２４Ｖ±１０％ＭＡＸＩＭＵＭＲＡＴＥＤ　ＣＵＲＲＥＮＴ　　１ＡＭＯＤＥＬＥＰＭ－ＲＵ－３－１ＣＯＤＥ　　　Ｎｏ．４２０１５０ＳＥＲＩＡＬ　Ｎｏ．１８１２００１Ｔ (4) Fringe board unit specification and serial No.
Page 9: Specifications And Overview
(1) The EPM system measures the lubrication flow and temperature at the lubrication point of the machine. (2) The EPM sensor information is sent to the relay board unit via the fringe board unit. (3) The relay board unit aggregates the fringe board unit information and sends it to the control-level equipment.
Page 10 (the contact must be ON). The time until the sensor returns differs depending on the system state and the individual difference between the EPM sensors. (5) When using the EPM sensor by itself, check the specification.
Page 11: Epm System Configuration Diagram
S: EPM sensor (thermocouple + contact) EPM sensor ID No.: 135 Group No. (1) The EPM sensor system consists of the relay board unit and the fringe board unit. (2) 6 EPM sensors can be connected to 1 fringe board unit.
Page 12: Epm Sensor Overview
EPM Sensor Overview The EPM system is installed at the end lubrication point of the lubrication system. When the lubricant flows, the internal contact opens and the flow is detected. In addition, the built-in temperature sensor monitors the temperature by indirectly measuring the lubrication point temperature.
Page 13 (1) By using the relay board unit and the fringe board unit, there is no need to worry that the metal part of the EPM body and the brown wire are conductive. When the relay board unit and the fringe board unit are used, the EPM body and the 24 VDC power are insulated.
Page 14 When directly connecting the EPM sensor (use of PNP or NPN allowed) (When not using the relay board unit or the fringe board unit) K type thermocouple DC3~24V 5mA capture unit MODEL EPM-L-01-W-2.5 CODE No. 420100 SERIAL No. 18 / 12 / 0001 / S...
Page 15 When connecting the EPM sensor to the total counter (When not using the relay board unit or the fringe board unit) DC3~24V 5mA MODEL EPM-L-01-W-2.5 CODE No. 420100 SERIAL No. 18 / 12 / 0001 / S Unconnected Unconnected Counter operation timing chart...
Page 16: Epm Sensor (Lhl Type)
Exterior: PVC  5.2, Length: 2500 mm Wire Four-line (for contacts/thermocouples) Minimum bending radius: 30 mm K type thermocouple (EPM sensor temperature is measured) Built-in temperature sensor (temperature of the lubrication point is measured indirectly) Temperature measurement 0C to 90C...
Page 17: Epm Sensor (Fs2 Type)
Exterior: PVC  5.2, Length: 2500 mm Wire Four-line (for contacts/thermocouples) Minimum bending radius: 30 mm K type thermocouple (EPM sensor temperature is measured) Built-in temperature sensor (temperature of the lubrication point is measured indirectly) Temperature measurement 0C to 90C...
Page 18: Epm Sensor (Oil Type)
Exterior: PVC  5.2, Length: 2500 mm Wire Four-line (for contacts/thermocouples) Minimum bending radius: 30 mm K type thermocouple (EPM sensor temperature is measured) Built-in temperature sensor (temperature of the lubrication point is measured indirectly) Temperature measurement 0C to 90C...
Page 19 Be sure to confirm that VCC is not short-circuited when checking discharge. (9) If you do not lubricate for a long time after installing the EPM sensor, the contact will not return properly. may become See Troubleshooting on page 67 please give me.
Page 20: Part Names/Dimensions Of Relay Board Unit
Part Names/Dimensions of Relay Board Unit 操作スイッチ Knob １５電源ランプ（緑色） Power LED (green) 表示器 Display エラーランプ（赤色） Alarm LED (red) ＶＯＬＴＡＧＥ　　　　　　　　ＤＣ２４Ｖ±１０％３ＭＡＸＩＭＵＭＲＡＴＥＤ　ＣＵＲＲＥＮＴ　　１ＡＭＯＤＥＬＥＰＭ－ＲＵ－３－１ＣＯＤＥ　　　Ｎｏ．４２０１５０ＳＥＲＩＡＬ　Ｎｏ．１８／１２／０００１Ｓ Transparent 透明カバー cover １６０６２１７５締め付けトルク０．４Ｎ・ｍ Tightening torque: 0.4 N∙m 保護キャップ　４箇所（Ｍ８メスコネクタ）　型式４２－１１７７２（ＣＯＮＥＣ）...
Page 21: Specifications Of Relay Board Unit
(maximum distance is 20 m when AWG20 wire is used) communication (maximum distance is 15 m when AWG23 wire is used) Up to 6 fringe board units per system (group) connectable (36 EPM sensors) Connection Maximum number of connections : 18 fringe board units : 108 EPM sensors...
Page 22: Part Names/Dimensions Of Fringe Board Unit
Part Names/Dimensions of Fringe Board Unit 末端基板ユニット用電源通信コネクタ（Ｍ８オスコネクタ） Power connector for fringe board unit (M8 male connector) ＥＰＭセンサー接続コネクタ　６箇所（Ｍ８メスコネクタ） EPM sensor connector at 6 places (M8 female connector) ＣＨ１ＣＨ２ＣＨ３ＣＨ４ＣＨ５ＣＨ６１２３１４．５１８１８１８１８１８１８...
Page 23: Specifications Of Fringe Board Unit
2-10 Specifications of Fringe Board Unit The unit aggregates the EPM sensor wires and sends measured values by communication. (Temperature measurement value, contact open time count value, contact ON-OFF information) Power supply 5 VDC (supplied from the relay board) voltage Communication LIN communication slave (temp., contact...
Page 24: Part Names/Dimensions Of Fringe Board Unit Mounting Plate
2-11 Part Names/Dimensions of Fringe Board Unit Mounting Plate １３５２－Ｍ４ｘ０．７　バーリング加工 Burring １１９Ｒ３．２５１１４－φ６．５長穴 Long hole ４－Ｒ２２１３７５３６９８５ｔ＝２１０１ Material: SUS304 １１７ (1) The mounting frame comes with the fringe board unit.
Page 25: Part Names/Dimensions Of M8 Branch Connector
2-12 Part Names/Dimensions of M8 Branch Connector Ｍ８オスコネクタ（Ｃｏｄｅ－Ａ） M8 male connector (code-A) ＨＥＸ９ φ３．２ Mounting hole ６２０．５１４．５３３Ｍ８メスコネクタ（Ｃｏｄｅ－Ａ） M8 female connector (code-A) Code No. 733574 Connection method 1 M8 Branch connector Connection method 2 M8 Branch connector...
Page 26: Model And Code No. List
2-13 Model and Code No. List Model Relay board unit EPM-RU-3-1 Number of Communication input ports form ＶＯＬＴＡＧＥ　　　　　　　　ＤＣ２４Ｖ±１０％ＭＡＸＩＭＵＭＲＡＴＥＤ　ＣＵＲＲＥＮＴ　　１ＡＭＯＤＥＬＥＰＭ－ＲＵ－３－１ＣＯＤＥ　　　Ｎｏ．４２０１５０ RS485 ＳＥＲＩＡＬ　Ｎｏ．１８／１２／０００１Ｓ 3 ports Model Fringe board unit EPM-EU-6 Number of input ports 6 ports...
Page 27 Model EPM sensor EPM-□-□-□-□-□ DC3~24V 5mA MODEL EPM-L-01-W-2.5-C CODE No. 420100 SERIAL No. TE20K0001 Lubricant used LHL-X100 Fitting size R1/8 M6 × 0.75 tapered M6 × 1.0 tapered M8 × 1.25 tapered Pipe connection  4 one-touch  4 bushing Wire length 2.5 m...
Page 28 420400 M8 2-core wire ASSY 5 m for alarm 420401 M8 2-core wire ASSY 10 m for alarm 420402 EPM extension wire ASSY 2.5 m 420410 EPM extension wire ASSY 5 m 420411 EPM extension wire ASSY 10 m 420412 * M8 and M12 connectors are both screw type connectors, which allow disassembly and reassembly.
Page 29 EPM sensor DC3~24V 5mA MODEL EPM-L-01-W-2.5-C CODE No. 420100 SERIAL No. TE20K0001 Model Code No. EPM-L-01-W-2.5-C LHL-W R1/8 420100 EPM-L-02-W-2.5-C LHL-W M6 × 0.75, tapered 420101 EPM-L-03-W-2.5-C LHL-W M6 × 1.0, tapered 420102 EPM-L-04-W-2.5-C LHL-W M8 × 1.25, tapered 420103 EPM-L-01-B-2.5-C...
Page 30 EPM sensor DC3~24V 5mA MODEL EPM-L-01-W-2.5-C CODE No. 420100 SERIAL No. TE20K0001 Model Code No. EPM-H-01-W-2.5 FS2-W R1/ 8, no C 420210 EPM-H-02-W-2.5 FS2-W M6 × 0.75, tapered, no C 420211 EPM-H-03-W-2.5 FS2-W M6 × 1.0, tapered, no C 420212 EPM-H-04-W-2.5...
Page 31 4-core wire 20 m for fringe board 733613 unit 2-core wire 20 m for alarm 733639 Blue wire 20 m for EPM sensor 733638 Rotation prevention bracket 650407 Fringe board mounting bracket 650408 * M8 and M12 connectors are both screw type connectors, which allow...
Page 32: Handling
3. Handling Environmental Conditions of Operation Use the EPM sensor in following environments. • Ambient temperature: 0 to +50°C • Humidity: 35 to 85% RH • For indoor use • Altitude: up to 2000 m • Pollution level: 2 Use the relay board unit in following environments.
Page 33: Disassembly/Cleaning/Assembly
Disassembly/cleaning/assembly If an abnormality occurs in the EPM sensor itself, the abnormality may be recovered by disassembling, cleaning, and reassembling according to the following procedure. ② ① Pallet ① ② Parts cleaner ③ Hand pump (10MPa boost) ④ Spanner (10mm, 11mm）...
Page 34 Cleaning ⑥ Clean the removed parts with parts cleaner. Be careful not to deform or damage parts when cleaning. 組立 ⑦ ⑧ Center the spring. recess facing up ⑨ Insert the piston with the recess facing up. ⑩ Insert in the orientation of the image. ⑪...
Page 35: Wiring
4. Wiring The wiring work must be carried out by a qualified electrician. See the figure below and check + and - before the work. The system does not work if + and - are wrongly connected. If the external lead lines from the 24 VDC power supply comes into contact with hands, the outside of the machine, or surrounding objects, use insulated wires.
Page 36: Wiring Between Epm Sensor And Fringe Board Unit
3 and 4. However, when using the fringe board unit, pins 1 and 2 must be shorted. If pins 1 and 2 are not shorted, it will be judged that the EPM sensor is not connected and an error will be output.
Page 37: Wiring Between Fringe Board Unit And Relay Board Unit
Wiring Between Fringe Board Unit and Relay Board Unit 16 mm 4 mm White: power output (5 V) Black: power output (0 V) Brown: fringe board unit communication Green: pump operation signal In operation: 5 V Non-operation: Open M8 female connector M8 male connector White: power output (5 V) Brown: fringe board unit...
Page 38 Power Communication Wiring of Relay Board Unit M12 female connector White: power input (24 V) 23 mm 7 mm Black: power input (0 V) Yellow: RS485 AY (+) Brown: RS485 BZ (-) Green: pump operation signal In operation: Short green and black wires. Non-operation: Open green and black wires.
Page 39: Alarm Wiring Of Relay Board Unit
Alarm Wiring of Relay Board Unit M8 male connector White: photo MOS output (+ side) 16 mm 4 mm Black: photo MOS output (- side) Maximum applied voltage: 26.4 VDC Maximum flowing current: 100 mA (when the temperature is 25°C) See page 63 of the instruction manual of the relay board unit.
Page 40: How To Connect M8 Connectors
Tighten the screw with a hexagonal wrench. * Appropriate tightening torque: 0.1 N∙m Hexagonal wrench size: 0.89 mm (Included with the EPM sensor) (5) Attach the housing with a housing nut. Attach the side cable sealing and the housing. Insert the cable in the connector.
Page 41: How To Connect M12 Connectors
How to Connect M12 Connectors Torque: 0.3 to 0.4 Nm Torque: 0.6 Nm Torque: 0.8 Nm or above 7 mm 30 mm 4 to 6 mm 5 to 8 mm Insert the cable in the connector.
Page 42: Relay Board Unit Setting
ID 6 (Dial code 1) (Dial code 2) (Dial code 3) (Dial code 4) (Dial code 5) (Dial code 6) Connection to relay board unit EPM sensor connection EPM sensor ID No.: 135 to 366 Group No. Fringe board unit...
Page 43: How To Set Dial Code (Id) Of Fringe Board Unit
How to Set Dial Code (ID) of Fringe Board Unit Knob Display Relay board unit CN11 Alarm output port Basic operation <1> How to display menu screen Press the knob, and display RUNNING “RUNNING” as shown on the left. Press the knob for 1 or MENU more seconds, and display >1.
Page 44 <2> How to set language MENU Display “MENU” shown on the >1. LANG left, and select “1. LANG”. Rotate the knob clockwise, and 2. ENG select “JPN”. >2. JPN * This is the setting step in Japanese. Rotate the knob clockwise, and 1.
Page 45 <3> How to set ID (dial code) As shown below, connect only 1 fringe board unit to system 1 of the relay board unit. * The default ID is set to 1. This setting should be made only when multiple terminal board units are to be connected.
Page 46: Overview Of Relay Board Unit Alarms
EPM sensor and the fringe unit. (The default setting is set by a PC.) The alarm is output when the wire of the EPM sensor is II. Disconnection error disconnected.
Page 47: Necessary Parts And Tools
(5) Fringe board unit (6) Relay board unit M12 wire ASSY M8 wire ASSY M8 alarm wire (7) 2-core wire (8) EPM sensor extension wire (9) M8 branch connector (10) PC (11) USB converter (12) 24 VDC power unit (provided by customer)
Page 48: Parts Description
(3) EPM sensor: 1 or more pcs • Use the attached thin spanner for mounting. • If the EPM sensor attached to the moving part rotates, use the attached rotation prevention bracket. • Wrap a seal tape around the mounting screw part.
Page 49 • Unusable for moving part • Rated voltage: 150 V, Rated temperature: 80°C (8) EPM sensor extension wire • It is used for extending the EPM sensor wire to 2.5 m or above. See page 27. (9) M8 branch connector •...
Page 50 (12) 24 VDC power unit • Use an NEC Class 2 power supply or a 2 A fuse. • Use a UL listed fuse. • Install the fuse near the equipment. • Use a power supply of 24 VDC and 30 W or above. •...
Page 51: Tools
(7) HEX13 spanner • It is used for tightening M8 connectors (tightening torque: 0.4 Nm). (8) HEX8-10 thin spanner • It is used for mounting EPM sensors (the spanner comes with the EPM sensor). • Thin spanner (thickness: 3.2 mm or below) (9) HEX9 thin spanner •...
Page 52: Fixtures
Fixtures (1) Large cable ties • T50R by HellermannTyton Co., Ltd. (2) Small cable ties • AB80-W by HellermannTyton Co., Ltd. (3) Insulation sleeves (4) Crimping terminals • 1.25Y-3.5 by NICHIFU Co.,Ltd. Others • Parts cleaner • Seal tape • Waste cloth •...
Page 53: Installation Method/Procedure
7. Installation Method/Procedure Step 1: Installation of Relay Board Unit First, determine the installation location of the relay board unit. Prepare the M5 screws for mounting. *See page 19 for mounting dimensions.
Page 54: Step 2: Installation/Wiring Of 24 Vdc Power Unit
Step 2: Installation/Wiring of 24 VDC Power Unit Install the 24 VDC power unit, and connect wires. Relay board unit M12 connector Relay board unit M12 wire ASSY 24 VDC power unit Relay board unit M12 wire ASSY DIN rail Relay 24 VDC WAGO...
Page 55: Step 3: Dial Code Setting Of Fringe Board Unit
Step 3: Dial Code Setting of Fringe Board Unit Turn on the power of the relay board unit, and set the dial code of the fringe board unit. * The default ID is set to 1. This setting should be made only when multiple terminal board units are to be connected.
Page 56: Step 4: Installation Of Fringe Board Unit
Step 4: Installation of Fringe Board Unit Determine the place for installing the fringe board unit, and install it. Use M4 screws for mounting. When tightening the fringe board unit together with the valve junction, use the fringe board mounting plate. Mounting bracket A junction of 1 to 7 ports is supported.
Page 57: Step 5: Mounting Epm Sensor
(12) The lubrication pipe length must be 2000 mm or below. (13) The minimum bending radius of the EPM sensor is 30 mm. The life of the pipe of the moving part is extended by making the bend large. (14) Make sure to release the air in the EPM sensor and the lubrication pipe.
Page 58 1.5 mm) * Note that excessive tightening causes grease leaks and damage. (1) Tighten the fixing screws for about 90° after they come into contact with the rotation prevention bracket. After tightening, check that the EPM sensor is firmly fixed.
Page 59: Step 6: Wiring Of Relay And Fringe Board Units
Step 6: Wiring of Relay and Fringe Board Units Connect the M8 connector of the relay board unit and the fringe board unit. Protect the M8 connector with a vinyl tape as necessary. M8 female connector Fringe board unit connection Tightening torque 0.4 Nm (5) Fringe board unit...
Page 60: Step 7: Alarm Wire Connection
Step 7: Alarm Wire Connection To output alarms to the outside, connect the wire to the alarm output port of the relay board unit. (6) Relay board unit M8 alarm wire Relay board unit Alarm output port (M8 female connector) 16 mm 4 mm White: photo MOS output (+ side)
Page 61 Output part Relay unit (Photo MOS) 1-pin Control circuit 4-pin Alarm output block diagram External device External device 1-pin 4-pin 1-pin 4-pin Connect the wire in accordance with the polarity of the external device. External device connection example Item Description Alarm output Photo MOS output Maximum applied voltage: 26.4 VDC (24 VDC + 10%), maximum flowing current:...
Page 62: Step 8: Pump Operation Signal Wiring
Step 8: Pump Operation Signal Wiring The pump operation signals are imported to the relay board unit. (See the circuit diagram in step 2.) Rated voltage: 150 V Rated temperature: 80°C Prepare another wire if the rated voltage is to be exceeded.
Page 63: Step 10: Installation Of Rs485 Converter Driver
Step 10: Installation of RS485 Converter Driver The RS485 converter driver is installed to the PC. Step 11: Setting of RS485 Converter Switch Set the switch of the USB-003. RS485 communication 1 ON → USB converter 2 0FF 1 ON 2 ON 3 ON 4 OFF...
Page 64: Step 12: Alarm Setting Of Relay Board Unit
* The setting can be performed by a single relay board unit. See the instruction manual of the relay board unit. Double-click Epm Config TooL.exe. How to write and read setting details Click this to use the setting that has been saved in the PC beforehand.
Page 65 The count value is decreased by 1 when the unit operates normally after the discharge error. In the communication setting, select COM port of the RS485 converter. Press Write Settings To EPM button to write the setting in the relay board unit.
Page 66: Step 13: Logging
Step 13: Logging Use the PC monitoring tool to perform logging. How to start logging software Double-click Epm Monitor.exe. USB connection port Click COM Setting → COM Port → USB connection port to be used. Monitor For monitoring, click → Start.
Page 67 Monitoring screen Group switching tab Contact/ temperature Fringe board switching tab unit ID switching tab Fringe board unit channel Temp. tab only Temp. axis scale Time axis scale Change the temperature scale/time axis to values that are easy to read.
Page 68: Troubleshooting
Symptom Cause Cause identification and solution The EPP sensor The lubrication Remove the EPM sensor, and use a does not open. part is clogged hand gun to check the lubrication load on the lubrication part. If the lubrication part is clogged up, remove it.
Page 69 Carry out disassembly, cleaning, and EPM sensor assembly See page 32. The reaction of There is air in Release the air in the lubrication the EPM sensor the lubrication pipe. is unstable. pipe and the Release the air in the continuous flow continuous flow valve.
Page 70 For Relay/Fringe Board Units Symptom Cause Cause identification and solution An error occurs when the connection configuration configuration is is insufficient or redundant with error is not not correct. respect to the configuration. Make corrected. the connection correct with respect to the configuration.