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AUTOL ALPB Series Product Manual

Progressive lubrication pump
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PRODUCT MANUAL
ALPB series
Progressive Lubrication pump

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Summary of Contents for AUTOL ALPB Series

  • Page 1 PRODUCT MANUAL ALPB series Progressive Lubrication pump...
  • Page 2 ALPB Pump Index Declaration of incorporation Legal disclosure Safety instructions Lubricant Technical data 8-30 Overview Working Principle Pump element 11-12 Safety valve SV - C / SV - A 13-15 Installation dimensions Low level indication 17-18 Integrated Controller and Monitoring 19-23 Internal and external wiring connections 24-32...
  • Page 3 The special documentation that responds to the machine, has been prepared according to annex VII- part B. The manufacturer (documentation department, phone +86 400 6836 862, email: info@autol.net) obliges itself to pass on electronically the special documentation for partly completed machinery to individual national authorities upon request.

  • Page 4: Legal Disclosure

    E-Mail: info@autol.net Website: www.autolgroup.com Training courses In order to provide a maximum of safety and economic viability, Autol Technology carries out detailed training courses. It is recommended that the training courses are attended. For more information, please contact Autol Technology. Copyright ©...

  • Page 5: Safety Instructions

    § Unauthorized modifications of the product § Intent or negligence § Use of non-original Autol Technology spare parts § Faulty planning or layout of the centralized lubrication system Liability for loss or damage resulting from the use of our products is limited to the maximum purchase price.

  • Page 6: Assembly And Maintenance

    The use of other parts may rule out liability for the consequences of such use. For components, which are retrofitted by the operator, Autol Technology does not assume liability nor claims for compensation. Danger caused by the electrics The units may be connected to the power supply exclusively by appropriately trained qualified personal in conformity with the local connection conditions and regulation (e.
  • Page 7 Cleaning The pump has an IP69 protection rating! It is not allowed to clean the Autol Technology pumps with a high-pressure washer. The high-pressure spray can allow water to penetrate the seals into the pump. We do not provide a warranty when high-pressure washers are used!

  • Page 8: Technical Data

    ALPB Pump Technical data Overview Autol Technology progressive centralized lubrication pump type - ALPB has been widely used in industries like wind power, mining, metallurgy, machine tools, textiles, food, ports, commercial vehicles, construction machinery, and heavy mechanical equipment, etc. Our Autol Technology automatic lubrication system lubricates all lube points as required through progressive lubrication system.
  • Page 9 Outside Diameter of Reservoir : 170 mm (adjusting of Safety Valve SV). The ALPB series pumps differ in reservoir size and control type. It can be controlled by the standard integrated controller with current version AK09* with LED display AK06, or externally by PLC, board computer or external controller from Autol Technology.

  • Page 10: Working Principle

    ALPB Pump Working Principle A gear DC motor ⑨ continually operates eccentric pressure disc ⑤. This eccentricity effects the suction and pressure strokes of the delivery piston ⑥, whereby the integrated non-return valve ⑦ prevents the delivery media from being sucked back out of the main line. The stirrer ②...

  • Page 11: Pump Element

    ALPB Pump Pump Element ALPB series pumps can be installed: - max. 4 pump elements with type C safety valve (SV-C without bypass) on the pump outlet position 1/2/3 - max. 3 pump elements with type A safety valve (SV-A with bypass) on the pump outlet position 1/3*.
  • Page 12 ALPB Pump Pump Element Function of Pump Element 15.1-1 On the vertical shaft of the geared DC motor an eccentric pressure disc EPD with eccentric hole in the centre is mounted. When the pump starts running the EPD will make a back-and-forth movement (X1, X2, X3). The pump element is mounted in the pump body the piston of the 15.1-2 pump element will run against the EPD.
  • Page 13 ALPB Pump Safety Valve Type C: SV-C for PE (Standard Version) Safety valve Type C: without bypass function Safety valve Type C: Pre-set to 300 bar When the system pressure is higher than the pre-set valve (300 bar), the safety valve opens, lubricant flows from the safety valve overflow port out.
  • Page 14 ALPB Pump Safety Valve Type A: SV-A for PE Safety valve Type A (SV-A): with bypass and indication pin function Safety valve Type A (SV-A): Pre-set to 300 bar When the system pressure is higher than the pre-set valve (300 bar), the safety valve opens, lubricant flows from the bypass of the safety valve and back to pump reservoir,indication pin moves out.
  • Page 15 ALPB Pump Grease Bypass Kit for Safety Valve Type A Single Bypass（Order No. 2031000878） In Dia. 18.2 shows the pump with safety valve type A and single bypass, which mainly used for Windmill application. When the pressure is higher than the pre-set max. value of the Dia.

  • Page 16: Installation Dimensions

    ALPB Pump Installation Dimensions ALPB BYN/HSC D230/D314 ALPB BYN/HSC D170 Installation Dimensions for ALPB BYN/HSC Pump (Stirring Paddle and Spring Piston Type) Capacity 2L D170 4L D170 4L D230 8L D230 15L D230 20L D230 20L D314 30L D314 A (mm) B (mm) H (mm)-Stirring Paddle Type-DC...
  • Page 17 ALPB Pump Low-level Indication(Stiring Paddle Type Pump) Functioning principle of the intermittent low-level indication The intermittent low-level indication operates free of contact. Its main components are the following: 1. Firmly positioned magnetic switch C inside of the reservoir bottom 2. Flexible guide plate E connected to the stirring paddle B with a magnet A 3.A control curved track D fixed on the perforated base plate If the reservoir is filled with a lubrication grease suitable for the intermittent low-level indication and the pump is operating, then the guide plate E is deflected by the resistance of the lubrication grease.
  • Page 18 ALPB Pump Low-level Indication(Spring Piston Type Pump) Functioning principle of the low-level indication The low-level inSdication operates free of contact. Its main components are the following: 1. The low level sensor A is installed and fixed inside the tie rod B 2.
  • Page 19 ALPB Pump LED Display AK06 with Integrated Controller AK09 Automatic Lubrication Monitor Dia. 21.1 AK06 LED- Display Our AK09 V5.3 controller / print board is the integrated setting adjustable controller for ALPB pumps series. The AK06 LED – Monitor / Display Universal works only in combination with the AK09 Setting adjustable controller which can be programmed with different program codes depending on the type (Standard Program Code for ALPB Stirring Paddle Type Pump...
  • Page 20 ALPB Pump LED Display AK06 with Integrated Controller AK09 Function and Display Pos. Sign Description Cycles Counting: During the pause time 1P, POS. 1 shows the number of finished lubrication cycles. The value of Count adds 1 after a full lube time. E.g., Count 168 means the system finished 168 lubrication cycles.
  • Page 21 ALPB Pump LED Display AK06 with Integrated Controller AK09 Parameter Setting – First connecting to power Dia. 23.1 Controller For first time connecting the power on the pump, the display shows program code the program code “d-56” up like Dia. 23.1 or other pump pre-set program code, depends on pump and software type.
  • Page 22 ALPB Pump LED Display AK06 with Integrated Controller AK09 Parameter Setting – Setup new parameter Press � button to switch to 4P Low temperature setting. With this parameter you can stop the pump working at low temperatures. Dia. 24.1 Setting of 4P - Pre-set temperature is –...
  • Page 23 ALPB Pump LED Display AK06 with Integrated Controller AK09 Restart of controller by switching off the machine In case power/machine is switched off during a lube Dia. 25.1 Cycle changing when power time P1 or pause time P3 following happens: switch ON and OFF during Pause time Switching machine on during 1P Pause Time, the 1P Pause time is counting down from the rest...
  • Page 24 ALPB Pump Wiring Connection (With integrated Setting adjustable Controller AK09 V5.3) ALPB BYN pump with 1 x BYN 7 pin connector + 1 x BD 4 pin connector – Solution for Divider Monitoring and External Test Button and Indication Light * The power is supplied to 12 or 24V DC motor of pump via the BYN 7 pin connector from Pos.
  • Page 25 ALPB BYN Ver. Pump Wiring Connection (With non-Controller AK09 WK2.0) ALPB BYN pump with 1 x BYN 7 pin connector– Solution for External Indication Light * The pump is supplied with 12/24V DC via the BYN 7-pin plug via Pos. A and the pump is not setting adjustable with lube time and pause time but controlled by power supply or external controller.
  • Page 26 ALPB Pump Wiring Connection (With integrated Setting adjustable Controller AK09 V5.3) ALPB HSC pump with 3 x HSC 4 pin connector–Solution for Power Supply,Divider Monitoring and External Test Button and Indication Light * The power is supplied to 12 or 24V DC motor of pump via the HSC 4 pin connector from Pos. A. Via Pos.
  • Page 27 ALPB Pump Pos. Qty. Description Part No. Wire kit-power supply-ALPB_HSC-12V DC-Int.-0,3m-HSC_M_4P-3xP_SNBM1.25-4_F-3x1 2031000529 Wire kit-power supply-ALPB_HSC-24V DC-Int.-0,3m-HSC_M_4P-3xP_SNBM1.25-4_F-3x1 2031000525 Wire kit-divider monitoring-ALPB_HSC-12/24V DC-Int.-0,3m-HSC_F-4P-3xP_JSTxH_F-3x0,5 2031000521 Wire kit-test button-ALPB_HSC-12/24V DC-Int.-0,3m-HSC_F-4P-2xP_JSTxH_F- 2031000660 2xP_JSTvH_F-4x0,5 Double terminal line-Black 2031001206 Controller-AK09-V5.3-programmable (print board)-program code d-56 for Stiring Paddle Type 2091000054 Pump Controller-AK09-V5.3-programmable (print board)-program code d-01 for...
  • Page 28 ALPB Pump Wiring Connection (With non-Controller AK09 WK2.0) ALPB HSC pump with 2 x HSC 4 pin connector–Solution for Power Supply and Indication Light * The power is supplied to 12/24V DC motor of pump via the HSC 4 pin connector from Pos. A and the pump is not setting adjustable with lube time and pause time but controlled by power supply or external controller.
  • Page 29 ALPB Pump Pos. Qty. Description Part No. Wire kit-power supply-ALPB_HSC-12V DC-Int.-0,3m-HSC_M_4P-3xP_SNBM1.25-4_F-3x1 2031000529 Wire kit-power supply-ALPB_HSC-24V DC-Int.-0,3m-HSC_M_4P-3xP_SNBM1.25-4_F-3x1 2031000525 Wire kit-test button-ALPB_HSC-12/24V DC-Int.-0,3m-HSC_F-4P-2xP_JSTxH_F- 2031000660 2xP_JSTvH_F-4x0,5 Double terminal line-Black 2031001206 Controller-AK09-WK-V2.0-12VDC-not programmable 2091000242 Controller-AK09-WK-V2.0-24VDC-not programmable 2091000205 Power Cable 7.5 meters - ALPB Hirschmann Connector 4 Pin-2*1-12/24V DC 2210000203 Test Button and Indication Light Cable 7.
  • Page 30 ALPB Pump Wiring Connection (With integrated Setting adjustable Controller AK09 V5.3) ALPB HSC pump with 3 x HSC 4 pin connector–Solution for Power Supply,Divider Monitoring and External Test Button and Indication Light * 230V AC power is supplied to the pump's 24V DC motor via the power converter via the HSC 4-pin connector at position A.
  • Page 31 ALPB Pump Pos. Qty. Description Part No. Wire kit-power supply-ALPB_HSC-230V AC-Int.-0,3m-HSC_M_4P-3xP_SNBM1.25-4_F-3x1 2031001246 Wire kit-divider monitoring-ALPB_HSC-12/24V DC-Int.-0,3m-HSC_F-4P-3xP_JSTxH_F-3x0,5 2031000521 Wire kit-test button-ALPB_HSC-12/24V DC-Int.-0,3m-HSC_F-4P-2xP_JSTxH_F- 2031000660 2xP_JSTvH_F-4x0,5 Wiring Set for Power Converter 2091000247 Controller-AK09-V5.3-programmable (print board)-program code d-56 for Stiring Paddle Type 2091000054 Pump Controller-AK09-V5.3-programmable (print board)-program code d-01 for Spring Piston Type 2091000368...
  • Page 32 ALPB Pump Wiring Connection (With non-Controller AK09 WK V2.0) ALPB HSC pump with 2 x HSC 4 pin connector–Solution for Power Supply and Indication Light * 230V AC power is supplied to the pump's 24V DC motor via the power converter via the HSC 4-pin connector at position A and the pump is not setting adjustable with lube time and pause time but controlled by power supply or external controller.
  • Page 33 ALPB Pump Filling of the Pump 1. Only use EP-2 lubricating greases that are approved for the various operating temperatures. 2. Keep the pump being vertical during the filling process. 3. When refilling the pump, the marking for the maximum filling level must not be exceeded. Check the filling process and complete it in time before the maximum fill level indicator is reached.
  • Page 34 ALPB Pump Explosion Drawing – ALPB Pump Body BYN + 2 - 4 Liter D170 Reservoir...
  • Page 35 ALPB BYN Ver. Pump Explosion Drawing – ALPB Stirring Paddle Type and Spring Piston Type BYN(DC) Pump Body Pos. Qty. Description Part No. 1.01 Hexagon socket head cap screw-DIN_EN_ISO_4762-M4x12-8.8-ST-ZnNi-including flat- and spring washer 3014000338 1.02-1 Perforated base plate-ALPB-D142x18-PL 3021000299 1.02-2 Bearing D10-26-H8 3014000627 1.03-1...
  • Page 36 ALPB BYN Ver. Pump Explosion Drawing – ALPB BYN (DC) Pump Body Pos. Qty. Description Part No. 1.27A-A Indication light-24VDC-red-M16 3031000197 1.27A-B Indication light-12VDC-red-M16 3031000198 1.27B-A Illuminated push button-24VDC-green_red_yellow-M16 3030000492 1.27B-B Illuminated push button-12VDC-green_red_yellow-M16 3030000491 1.28-1A Wire kit-power supply-ALPB_BYN-12VDC-Int.-0,3m-BYN_M_7P-4xP_JSTxH_F-3xP_JSTvH_F-7x0,5 2091000053 1.28-1B Wire kit-power supply-ALPB_BYN-24VDC-Int.-0,3m-BYN_M_7P-4xP_JSTxH_F-3xP_JSTvH_F-7x0,5 2091000051...
  • Page 37 ALPB Pump Explosion Drawing – ALPB HSC(DC and AC) Pump Body + 2 - 4 Liter D170 Stirring Paddle Type Reservoir 1.31 1.30 1.29 2.06 2.01 2.07 2.08 2.02 1.33 1.32 2.03 2.04 1.34 1.35 2.05 1.36 2.09 1.37 1.01 1.36 1.38 1.02...
  • Page 38 ALPB Pump Explosion Drawing – ALPB Stirring Paddle Type and Spring Piston Type HSC(DC and AC) Pump Body Pos. Qty. Description Part No. 1.01 Hexagon socket head cap screw-DIN_EN_ISO_4762-M4x12-8.8-ST-ZnNi-including flat- and spring washer 3014000338 1.02 Perforated base plate-ALPB-D142x18-PL 3021000299 1.03 Bearing D10-26-H8 3014000627 1.04-1...
  • Page 39 ALPB Pump Explosion Drawing – ALPB Stirring Paddle Type HSC (DC and AC) Pump Body Pos. Qty. Description Part No. 1.29-1A Wire kit-power supply-ALPB_HSC-12V DC-Int.-0,3m-HSC_M_4P-3xP_SNBM1.25-4_F-3x1 2031000529 1.29-1B Wire kit-power supply-ALPB_HSC-24V DC-Int.-0,3m-HSC_M_4P-3xP_SNBM1.25-4_F-3x1 2031000525 1.29-1C Wire kit-power supply-ALPB_HSC-230V AC-Int.-0,3m-HSC_M_4P-3xP_SNBM1.25-4_F-3x1 2031001246 1.29-2 Cylinder Screw with Cross Groove M3 L10-A2 3014000236 1.29-3 Connecter gasket...
  • Page 40 ALPB Pump Explosion Drawing: 8 – 20 Liter D230 Reservoir ALPB Stirring Paddle Type Pump 6.01...
  • Page 41 ALPB Pump General BOM - ALPB Stirring Paddle Type Pump Reservoir Kit - 1 (2 - 20 L) Pos. Qty. Description Part No. 2.00A Kit-grease reservoir attached to pump body-ALPB-D170-2L-(full package) * (incl. 2.01-2.09) 2.00B Kit-grease reservoir attached to pump body-ALPB-D170-4L-(full package) * (incl. 2.01-2.09) 2.01-1 Hexagon acorn nut-DIN_1587-M6-6_A2-SS 3014000292...
  • Page 42 ALPB Pump General BOM - ALPB Stirring Paddle Type Pump Reservoir Kit - 2 (2 - 20 L) Pos. Qty. Description Part No. 4.03 Kit ventilation-grease reservoir-ALPB 2031001165 4.04A T-rod for grease distribution at reservoir-ALPB-D230-15L-D10-L417-ST-ZnNi 3012000386 4.04B T-rod for grease distribution at reservoir-ALPB-D230-20L-D10-L560-ST-ZnNi 3012000387 4.05A 0 or 4 Tie-rod for grease reservoir-ALPB-D230-15L-D7-M6-L452-ST-ZnNi-for with top cover bracket...
  • Page 43 ALPB Pump Explosion Drawing: 4 - 15 Liter D230 Reservoir ALPB Spring Piston Type Pump 3.01-1 6.01 3.01-2 2.01-1 3.02 2.01-2 3.10 3.03 2.02 3.04 2.03 2.10 3.11 2.04 3.05 3.06 3.12 2.05 2.06 3.13 2.11 3.07 2.07 3.14 2.12 3.08 2.08 3.15...
  • Page 44 ALPB Pump Explosion Drawing: 4 - 15 Liter D230 Reservoir ALPB Spring Piston Type Pump 4.21 4.01-1 4.22 4.01-2 4.02 4.03 4.10 4.04 4.11 4.12 4.05 4.06 4.13 4.14 4.07 4.15 4.08-1 4.16 4.08-2 4.17 4.18 4.09 4.19 4.20...
  • Page 45 ALPB Pump Explosion Drawing: 20 – 30 Liter D314 Reservoir ALPB Spring Piston Type Pump 5.10-1 5.10-2 5.11 5.01 5.12 5.02 5.13 5.22 5.03 5.14 5.04 5.05 5.14 5.06 5.07 5.15 5.08 5.16 5.17 5.18 5.19 5.09 5.20 5.21...
  • Page 46 ALPB Pump General BOM - ALPB Spring Piston Pump Reservoir Kit - 1 (4 and 8 L) Pos. Qty. Description Part No. 2.00 Kit-grease reservoir attached to pump body-ALPB-D230-4L-(full package) * (incl. 2.01-2.17) 2.01-1 Min. level sensor-ALPB Spring Piston Pump 2031001285 Sensor retaining sleeve-4L-D9-7×200 2.01-2...
  • Page 47 ALPB Pump General BOM - ALPB Spring Piston Pump Reservoir Kit - 2 (15 L) Pos. Qty. Description Part No. 4.00 Kit-grease reservoir attached to pump body-ALPB-D230-15L-(full package) * (incl. 4.01-4.22) 4.01-1-1 Min. level sensor-ALPB Spring Piston Pump-15L 2031000881 4.01-1-2 Connector sheath-18×18 3020000239 Connector gasket-31.9×31.9×15-NBR...
  • Page 48 ALPB Pump General BOM - ALPB Spring Piston Pump Reservoir Kit - 3 (20 and 30 L) Pos. Qty. Description Part No. 5.00A Kit-grease reservoir attached to pump body-ALPB-D314-20L-(full package) * (incl. 5.01-5.21) 5.00B Kit-grease reservoir attached to pump body-ALPB-D314-30L-(full package) * (incl. 5.01-5.22) 5.01-1 Hexagon head bolt (perforated)-M8_A2-SS 3012002785...

  • Page 49: Delivery, Returns And Storage

    Storage Autol Technology products are subject to the following storage conditions: § dry, dust- and vibration-free in closed premises § no corrosive, aggressive materials at the place of storage (e. g. UV rays, ozone) §...

  • Page 50: Place Of Installation

    ALPB Pump Step for Storage period from 6 to 18 months - Hose 1. Dismantle preassembled hose 2. Ensure that both sides of the hose remain open 3. Fill hose with new lubricant Storage period exceeding 18 months To avoid dysfunctions, consult the manufacturer before commissioning. The general procedure to remove the old grease filling corresponds to that of a storage period from 6 to 18 months Installation General information...
  • Page 51 ALPB Pump - Electrical connection Electric shock Make sure to disconnect the product from the power supply before carrying out any works on electrical components. Carry out the electrical connection according to the connection type of the pump, 1. Tailor the line for the power supply according to the respective connection diagram in these instructions or use pre-fabricated cable.

  • Page 52: Troubleshooting

    ALPB Pump Trouble shooting Fault Possible cause Solution Pump does not run § Power supply to pump interrupted Check whether one of the indicated faults is present and - Superior machine is switched off remedy it in the frame of - Connection cable of pump is responsibilities.

  • Page 53: Shutdown And Disposal

    ALPB Pump  Defect of the safety valve Signal for a defected safety valve – the lubricant comes out from the safety valve. Dismount the main hose from the outlet of the safety valve and use a blind plug on the outlet. Check the pressure of the manometer, if the safety valve opens under 180bar, replace the safety valve.
  • Page 54 ALPB BYN Ver. Pump Order Key...

This manual is also suitable for:

Alpb101Alpb121Alpb130

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