SUREFIRE PDIOPERATORSMANUAL Single Phase Models(24VDC, 115VAC and 230VAC)
2
35022E R6-08/16
IndexGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Precautions and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Design and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Wiring Diagram – Terminal Block Connections . . . . . . . . . . . . . . . . . . .6-8
Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Timer settings (for use with optional timer) . . . . . . . . . . . . . . . . . . . . . .10
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Wiring Diagram – Timer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
How To Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
GeneralBefore installing this lubricator, please read this manual carefully.
Failure to follow these instructions can result in damage to
the product and/or serious bodily injury. The SureFire PDI
lubricator meets all of the operating parameters for Bijur Positive
Displacement Injector (PDI) centralized lubricating systems.
©Copyright Bijur Lubricating Corporation 2004-2006. Bijur Lubricating Corp. reserves the right to update or improve the technical specifi cations for this product without prior notice.
Company Headquarters and Sales/Service:Bijur Delimon International2100 Gateway Centre Blvd., Suite 109Morrisville, North Carolina 27560-6600USAPhone: (800) 631-0168Fax: (919) 465-0516
ApplicationThis SureFire PDI lubricator is ideally suited for use in single-line
centralized lubrication systems. In these systems, lubricant is
being delivered in pulses and under pressure (pressure and relief
cycles) through the main feed lines to Positive Displacement
Injectors (PDI’s) located near the lube points of the machinery
being lubricated. Every use beyond this type of application is not
in accordance with the manufacturers’ intended purpose, and the
manufacturer is not to be held responsible for any damages result-
ing from it. The corresponding risk is taken by the user only.
SafetyThis Operators Manual covers fundamental concepts, which are to be
observed for installation, operation and maintenance. Therefore, it
is absolutely necessary that the Operating Manual be studied by the
person doing the installation prior to installation and start-up. It is also
necessary to have this Operators Manual nearby and available for refer-
ence in the future. The safety instructions mentioned in this
Operators Manual, as well as all national operating and safety regula-
tions for the safe operation of such equipment are to be observed.
Precautions and symbolsGeneral precautions and symbols used within this manual are as follows:
General safety instructions
Electrical safety instructions
Safety instructions which shall be considered for
reasons of safe operation of the lubricator
Electrical connections made to Earth ground are
identified by this symbol
Electrical connections made to the Neutral
conductor are identifi ed with a capital “N” NConditions and actions that pose potential hazards
to the user are marked by this sign
All safety and/or warning labels affi xed to the SureFire PDI lubricator must
be maintained in a completely legible condition. Also, any modifi cations
made to the SureFire PDI lubricator (or to any of its components) must be
approved by Bijur Lubricating Corp. prior to its use, otherwise the warran-
tee and any liability by Bijur Lubricating Corp. will be null and void.
Design and ConstructionThe basic design of the SureFire PDI lubricator is that of a motor driven
gear pump, which sits in a reservoir of lubricant. The motor, gear pump
and connecting driveshaft are assembled as a self-contained unit and
are “dropped into” the reservoir through a hole in the main structural
component, the Top Plate.
Installing the motor and pump assembly into th0e reservoir from the top
provides easy access to all of the motor and pump components, includ-
ing the screen (if applicable) without having to disassemble the reser-
voir. If detaching the reservoir from the Top Plate is necessary, it can
be done easily and without any tools on all models other than the 12
liter models, by loosening the external latches that are located on either
side of the lubricator. On all models other than the 12 liter models, the
Top Plate is mounted to the customer equipment by means of two bolts,
and also provides the mounting locations for all of the other lubricator
components. The 12 liter models are supported from the bottom.
The motor, pump and driveshaft assembly delivers pressurized lubri-
cant directly into a channel in the Top Plate. This channel is sealed by
means of O-Rings, and gives the Top Plate two integral outlet ports, one
located at each end. Therefore, the customer may connect the main
line plumbing distribution network to either side of the Top Plate, or to
both sides, whichever is more convenient or aesthetically pleasing.
35022E R6-08/16
Technical Specifi cationsOutput Volume: 115 VAC, 230 VAC: 200cc/min @ 60Hz (167cc/min @ 50
Hz) 24VDC: 250cc/min
Output Pressure (MAX.): 450 psi (31 bar). This is the pressure relief
valve setting.
Pressure Switch: Standard, closes at 290 ±5 psi (20 ±0.3 bar)
Lubricant Viscosity: Oil, 20-1500 cp, Fluid greases, NLGI 000-00, 1500-
40,000 cp
Output Connection to Distribution: G1/4 BSPP (minimum 6MM OD main
distribution line tubing recommended)
Reservoir Fill Screen: 40 mesh, removable
Reservoir Volume: 1.8 Liters, 2.7 Liters, 6.0 Liters, 12.0 Liters
Reservoir Material: Clear ABS Plastic for 1.8, 2.7 and 6.0L, Steel for
12.0L
Motor Voltage Options: 24VDC, 115VAC 50/60 Hz, 230VAC 50/60 Hz
Motor Overload Protection needs to be provided by the host machine
and/or its control system.
Motor Power Requirements: Approx. 140W
Motor Duty Cycle (for 115VAC and 230VAC motors): S3, 20%. This means
that the maximum continuous “ontime” for any cycle is 3 minutes, and
if the motor continuous “ontime” for a cycle is X, the required minimum
“offtime” for that same cycle is at least 5X. Each motor has an internal
high temperature cutoff switch.
Motor Duty Cycle (for 24VDC motor): S1 (Continuous Duty).
Operating Temperature Range: +5°C through +40°C (+40°F through
+105°F)
Environmental Conditions: For indoor use only.
Relative humidity: 80% up to 31°C decreasing linearly to 50% at 40°C
Sound Pressure: 70 dBA
IP Rating: IP-54
Dry Weights SF2BxxB or C or D: 9.0 lbs/4.08 Kg
SF3BxxB or C or D: 10.0 lbs/4.54 Kg
SF6BxxB or C or D: 11.25 lbs/5.10 Kg
SF12BxxB or C or D: 16.0 lbs/7.26 Kg
Current Draw and Power Consumption
Rated Voltage (+/- 10%) 24VDC 115 & 230VAC
(60 Hz, 1 Phase)
Peak Starting Current (amps) 4.0 2.4/1.1
Normal Running Current (amps) 2.4 2.2/.95
Max. Current locked rotor (amps) 5.2 3.0/1.44
Discharge (cc/min) 250 60Hz 200/200
50Hz 167/167
NOTE: 1) Peak and Starting Currents were measured with 40,000cp fl uid at 450 psi.
output pressure. 2) Discharge fl ows were measured with 0 psi output pressure. 3)
Bijur Delimon recommends a 10A power supply for 24VDC motor.
The SureFire PDI lubricator must not be used in explosive atmospheres and must not be used for pumping fl ammable liquids.
Principle of OperationWhen power is supplied to the motor (via either an on-board timer
or controller or by customer-supplied power) the motor runs the gear
pump. As the motor turns, the gear pump pulls lubricant in from the
reservoir and delivers pressurized lubricant to the distribution network
via the outlet(s) in the Top Plate. Pressurizing the distribution net-
work forces all of the PDIs in the system to ”fi re”, or to discharge the
lubricant that was stored in each of their discharge chambers during
the last pump cycle. Once all of the PDIs discharge and the distribu-
tion network “deadheads”, the pressure in the network continues to
rise until the limit in the pressure switch is reached. Once this limit
is reached, the pressure switch can be used to stop the motor. Once
the motor stops, momentary pressure in the distribution network is
greater than the pressure at the outlet side of the gear pump. This
pressure differential actuates a quick dump valve which relieves the
distribution line pressure back into the reservoir. This line pressure
relief allows each PDI in the distribution network to reset by allowing
its internal spring to fi ll its discharge chamber once again. The above
described PDI discharge and recharge cycle repeats itself every time
the motor is switched on, the PDIs discharge then deadhead, and the
motor is switched off.
When the system is at rest; when all PDIs have recharged and before
the next motor cycle is started, a small check valve in the distribution
line always maintains a positive distribution system line pressure of
anywhere from 5 to 10 psi. This is to prevent the possibility of ever
allowing any air into the system should a leak ever occur anywhere
in the distribution network. Bijur’s philosophy with regard to using
this check valve is: it’s better to have, and notice, and hopefully fi x, a
small positive leak in the distribution network, than have to solve the
problems of removing entrained air bubbles somewhere in the lines,
which usually means fi xing the initial leak and bleeding the entire
system.
In the SureFire PDI models that come equipped with an on-board
timer or controller, the frequency of the cycling is programmed auto-
matically to be either time dependent or machine event dependent
(ex. triggered by a proximity switch). Also, if the pressure switch ever
becomes faulty, any over-pressure situation in the distribution network
is always relieved back into the reservoir by means of a pressure relief
valve set at a level safe for Bijur Positive Displacement Injectors. A
low-lubricant level switch is standard on all SureFire PDI models as
well, and can be used to prevent operation of the lubricator once the
level of lubricant in the reservoir falls below a set minimum level. In
this case, the motor is prevented from running and a fault condition
on the controller is generated and/or a fault light is illuminated.
Also, on all SureFire PDI models that have an on-board controller, the
pressure building aspect of the system is monitored to detect if there
might be a possible leak in the distribution system. More specifi -
cally, the time elapsed from the “motor start” event to the “pressure
switch” event is monitored, and if too much time is taken between
these two events, a leak in the distribution network is assumed, the
motor is subsequently prevented from running and a fault condition
on the controller is generated and/or a fault light is illuminated. On
all SureFire PDI models that have an on-board controller, once a fault
condition is generated, it is cleared by the next successful lube cycle
and pressure switch actuation.
All SureFire PDI models come with an LED that illuminates when the
motor shaft is actually turning, and a Momentary On/Off Switch that
can be used for manual priming if the customer so desires. For all
SureFire PDI models that come with an on-board timer or controller,
the Momentary On/Off Switch is pre-wired at the factory.
3
4
35022E R6-08/16
4
SureFire PDI1.8L, 2.7L, 6.0L (24VDC, 115VAC and 230VAC models)(on-board timer or controller not available with 1.8L reservoir size)
Overall Dimensions
C
B
N
A
N
E
KD
F
G
H
J
P
U
RQ
Q
S
TML
T
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Français Français
English
SureFire Reference A B C D E F G H J K L M N P Q R S T U
1.8L 136 114 82 174 170 285 230 183 204 154 141 154 25 153 5 6 5 175 N/A
2.7L 139 114 82 174 256 285 230 269 279 154 141 154 25 233 5 6 5 175 215
6.0L 186 117 85 204 290 318 264 303 N/A 187 174 187 25 220 5 35 5 209 N/A
(all dimensions are in millimeters)
(todas las dimensiones estan en milímetros)
(alle Abmessungen in Millimeter)
(toutes les dimensions sont en millimètres)
English
eutschg
spañol
spañol
35022E R6-08/16
5
Overall Dimensions
SureFire PDI 12.0 Liter (24VDC, 115VAC and 230VAC models)(all dimensions are in millimeters)
(todas las dimensiones estan en milímetros)
(alle Abmessungen in Millimeter)
(toutes les dimensions sont en millimètres)
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eutschg
spañol
spañol
English
Español
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Deutsch
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Deutsch
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6
35022E R6-08/16
6
Terminal Block Connections - 115VAC
Grease Version
Oil Version
(5) Jumpers as shown(5) puentes según lo demostrado(5) Überbrückungsdrähte (Verbindungsleiter) wie gezeigt(5) pullovers comme montré
White/ Blanco/ Weiß / Blanc
Black/ Negro/ Schwarzes/ Noir
Blue/ Azul/ Blau/ Bleu
Red/ Rojo/ Rot/ Rouge
Momentary "on" switch/ Interruptor momentáneo de "on"
Momentschalter “AN”/ Commutateur momentané de "on" 12
11
Led / Conducido / Mené 1
Level switch/ Interruptor de nivel/ Füllstandschalter / Commutateur de niveau
Pressure switch / Interruptor de presión / Druckschalter / Mano-contact
115VAC (-) 5
(Do not use) / (no el uso) / (nicht verwenden) / (pas l'utilisation)
115VAC (+) 2
(Customer option)/ (Opción del cliente)/ (Wahl des Kunden)/ (Option de client)
Ground / Tierra / Erde / La terre 0
ENG
ESP
FR
DE
Led / Conducido / Mené 6
14
13
10
9
8
7
4
3
115VAC
M
Brown/ Marrón/ Braun/ Brun
L-
L+
White/ Blanco/ Weiß / Blanc
Black/ Negro/ Schwarzes/ Noir
Blue/ Azul/ Blau/ Bleu
Red/ Rojo/ Rot/ Rouge
M
11
10
910.....30VDC (+)
Output (+) 200mA10.....30VDC (-)
(5) Jumpers as shown(5) puentes según lo demostrado(5) Überbrückungsdrähte (Verbindungsleiter) wie gezeigt(5) pullovers comme montré
Level switch (N.O)Interruptor de nivel (N.O) Füllstandschalter (N.O)Commutateur de niveau (N.O)
ENG
ESP
FR
DE
ENG
ESP
FR
DE
Black/ Negro/ Schwarzes/ Noir
Blue/ Azul/ Blau/ Bleu
Momentary "on" switch/ Interruptor momentáneo de "on"
Momentschalter “AN” / Commutateur momentané de "on" 13
12
Led/ Conducido/ Mené 1
Pressure switch/ Interruptor de presión/ Druckschalter/ Mano-contact
115VAC (-) 5
(Do not use)/ (no el uso)/ (nicht verwenden)/ (pas l'utilisation)
115VAC (+) 2
(Customer option)/ (Opción del cliente)/ (Wahl des Kunden)/ (Option de client)
Ground/ Tierra/ Erde/ La terre 0
Led/ Conducido/ Mené 6
15
14
8
7
4
3
115VAC
7
35022E R6-08/16
Terminal Block Connections - 230VAC
7
Grease Version
Oil Version
(4) Jumpers as shown(4) puentes según lo demostrado(4) Überbrückungsdrähte (Verbindungsleiter) wie gezeigt(4) pullovers comme montré
White/ Blanco/ Weiß / Blanc
Black/ Negro/ Schwarzes/ Noir
Blue/ Azul/ Blau/ Bleu
Red/ Rojo/ Rot/ Rouge
Momentary "on" switch/ Interruptor momentáneo de "on"
Momentschalter “AN”/ Commutateur momentané de "on" 12
11
Led / Conducido / Mené 1
Level switch/ Interruptor de nivel/ Füllstandschalter / Commutateur de niveau
Pressure switch / Interruptor de presión / Druckschalter / Mano-contact
230VAC (-) 5
(Do not use) / (no el uso) / (nicht verwenden) / (pas l'utilisation)
230VAC (+) 2
(Customer option)/ (Opción del cliente)/ (Wahl des Kunden)/ (Option de client)
Ground / Tierra / Erde / La terre 0
ENG
ESP
FR
DE
Led / Conducido / Mené 6
14
13
10
9
8
7
4
3
230VAC
M
(4) Jumpers as shown(4) puentes según lo demostrado(4) Überbrückungsdrähte (Verbindungsleiter) wie gezeigt(4) pullovers comme montré
White/ Blanco/ Weiß / Blanc
Black/ Negro/ Schwarzes/ Noir
Blue/ Azul/ Blau/ Bleu
Red/ Rojo/ Rot/ Rouge
Momentary "on" switch/ Interruptor momentáneo de "on"
Momentschalter “AN”/ Commutateur momentané de "on" 12
11
Led / Conducido / Mené 1
Level switch/ Interruptor de nivel/ Füllstandschalter / Commutateur de niveau
Pressure switch / Interruptor de presión / Druckschalter / Mano-contact
230VAC (-) 5
(Do not use) / (no el uso) / (nicht verwenden) / (pas l'utilisation)
230VAC (+) 2
(Customer option)/ (Opción del cliente)/ (Wahl des Kunden)/ (Option de client)
Ground / Tierra / Erde / La terre 0
ENG
ESP
FR
DE
Led / Conducido / Mené 6
14
13
10
9
8
7
4
3
230VAC
M
8
35022E R6-08/16
Terminal Block Connections - 24VDC
Grease Version
Oil Version
8
(3) Jumpers as shown(3) puentes según lo demostrado(3) Überbrückungsdrähte (Verbindungsleiter) wie gezeigt(3) pullovers comme montré
Momentary "on" switch/ Interruptor momentáneo de "on"
Momentschalter “AN”/ Commutateur momentané de "on" 12
11
Led / Conducido / Mené 1
Level switch/ Interruptor de nivel/ Füllstandschalter / Commutateur de niveau
Pressure switch / Interruptor de presión / Druckschalter / Mano-contact
24VDC (+) 5
(Do not use) / (no el uso) / (nicht verwenden) / (pas l'utilisation)
24VDC (-) 2
(Customer option)/ (Opción del cliente)/ (Wahl des Kunden)/ (Option de client)
Ground / Tierra / Erde / La terre 0
ENG
ESP
FR
DE
Led / Conducido / Mené 6
14
13
10
9
8
7
4
3
24VDC
M
Black/ Negro/ Schwarzes/ Noir
Orange/ Anaranjado
L+
L-
Brown/ Marrón/ Braun/ Brun
11
10
910.....30VDC (+)
Output (+) 200mA10.....30VDC (-)
(3) Jumpers as shown(3) puentes según lo demostrado(3) Überbrückungsdrähte (Verbindungsleiter) wie gezeigt(3) pullovers comme montré
Level switch (N.O)Interruptor de nivel (N.O) Füllstandschalter (N.O)Commutateur de niveau (N.O)
ENG
ESP
FR
DE
ENG
ESP
FR
DE
Black/ Negro/ Schwarzes/ Noir
Blue/ Azul/ Blau/ Bleu
Momentary "on" switch/ Interruptor momentáneo de "on"
Momentschalter “AN” / Commutateur momentané de "on" 13
12
Led/ Conducido/ Mené 1
Pressure switch Interruptor de presión/ Druckschalter/ Mano-contact
24VDC (+) 5
(Do not use)/ (no el uso)/ (nicht verwenden)/ (pas l'utilisation)
24VDC (-) 2
(Customer option)/ (Opción del cliente)/ (Wahl des Kunden)/ (Option de client)
Ground/ Tierra/ Erde/ La terre 0
Led/ Conducido/ Mené 6
15
14
8
7
4
3
24VDCBlack/ Negro/ Schwarzes/ Noir
Orange/ Anaranjado
M
9
35022E R6-08/16
Install the SureFire PDI Lubricator in
the horizontal position ONLY. Attach
the lubricator in the desired loca-
tion and to the desired equipment by
means of an appropriately sized bolt
through each of the (2) mounting holes
in the top plate. For the 1.8 and 2.7
liter models, use (2) M6 bolts. For the
6.0 liter models, use (2) M8 bolts.
For the 12.0 liter models, support the
reservoir from the bottom.
Reservoir size Hortizontal distance between mounting bolts Use bolt
1.8 153MM +5/ -0 M6
2.7 215MM +5/-0, 233MM +5/-0 M6
6.0 220MM +5/-0 M8
12.0 ——— ——
The lubricator should be installed in a location that is easy to access, for
purposes of viewing the front panels, for ease of reservoir-fi lling, for ease of
service and for ease of attachment to the distribution network plumbing.
Remember the SureFire PDI allows attachment of distribution plumbing to
either (or both) sides of the top plate. If only one side is used, be sure to
plug the unused outlet with a G1/4 BSPP plug (one such plug is included
with each lubricator). Also, the reservoir on the 1.8L, 2.7L and 6.0L mod-
els can be easily removed by loosening the latches located on ether side
of the lubricator. However, to successfully do this, be sure to leave enough
clearance underneath the lubricator to allow for the reservoir to be dropped
down appropriately.
Two liquid tight fi ttings are supplied with the lubricator. Use the liquid
tight fi ttings to secure the electrical wiring for the lubricator and to prevent
ingress of fl uids or dirt into the motor compartment. Typically one of the
fi ttings is used to bring “power” into the motor compartment and the other
fi tting is used to bring “signal” into or out of the motor compartment.
All tubing, fl exible hoses and fi ttings must be compatible with the lubri-
cant, operating pressure and surrounding environment. In general, try to
install the lubricator in the lowest position (vertically) with relation to the
rest of the distribution network and do not allow the tubing to rise and fall
when avoiding obstacles. This is in case air enters the distribution lines, the
bubbles will tend to rise towards the end of the distribution lines and not
get caught anywhere along the way. Any air bubbles trapped in the distribu-
tion network plumbing may prevent the PDI injectors from working properly.
Utilize the pressure switch to provide electronic monitoring of the lubricat-
ing cycles. For systems having more than 8 meters (25 feet) of main line
tubing, disconnect the pressure switch that is located under the motor
cover of every SureFire PDI lubricator, and install it downstream in the
distribution network; after the last PDI injector or bank of PDI injectors.
IMPORTANT: in this case, also be sure to plug and seal the tapped hole in
the SureFire PDI top plate with a G1/8 BSPP plug and sealing ring where
the pressure switch adapter was originally located, or with a 1/8 NPT plug
into the adapter where the pressure switch was originally located.
All electrical connections are to be made by a quali-
fi ed technician and all local electrical codes are to be followed. When
electrical connections are being made, do so before the power leads are
connected and before the power is supplied.
Consult the wiring diagram (located under the motor cover) for the correct
wiring for your SureFire PDI lubricator.
The installation should include a means of discon-
necting the power supply for servicing. Such means shall allow for switch-
ing off the power during normal operation and/or in an emergency. Also, a
residual current device is required to automatically disconnect the power
supply in the event of a failure in basic insulation.
This appliance should be protected against overcurrent by fi tting an ap-
propriate circuit breaker or fuse on the mains supply line.
Fuse Specifi cation110/220VAC: 3A, 250V, quick-acting, 5x20mm, ceramic to BS4265 or to
IEC127. UL recognition.
24VDC: 5A, 32V, automotive to SAEJ1284. UL recognition.
Be sure that all plumbing distribution lines are clean, are not kinked and
are free from any chips or any other impurities.
Fill the reservoir through the fi ll cap and/or fi ll cap strainer
with clean lubricant specifi ed by the Original Equipment Manufacturer
and that meets all of the lubricant specifi cations listed below.
Lubricant viscosity Oil, 20–1500 cp
Fluid grease, NLGI 000 to 00, 1500–40,000 cp
Do not overfi ll the reservoir. Never fi ll past the “MAX” level
as noted on the reservoir. Overfi lling could cause damage to the electrical
components located under the motor cover.
Pump primingFilling the reservoir and turning on the lubricator is usually enough to
prime the pump. However, in the case of a very thick lubricant, sometimes
it’s necessary to assist priming the pump. Upon initial startup, if no lubri-
cant is being delivered to the pump outlet, make sure the pump is primed.
Avoid all kinds of impurities as dirt particles are the most common cause
of gear pump failure. If you wish to determine whether the lubricant you
plan on using is approved for use with Bijur Lubricating Systems, you can
consult the Customer Service Department.
To prime the distribution network, plumb the entire system (mainline tub-
ing, manifolds, junctions, air/oil blocks, injectors, injector outlet tubing to
bearing points, etc.). Then, remove a plug or injector at the point furthest
away from the pump. Now, run the pump until bubble-free lubricant fl ows
from this point. Replace the plug or last injector.
Installation and Commissioning
9
Reservoir latch
Right view
G 1/4 BSPP (Min. 6mm O.D. main distribution line tubing recommended)
35022E R6-08/16
Maintenance and ServiceThe SureFire PDI lubricator does not require much maintenance. After
initial set-up, the lubricator requires only the following maintenance:
a) When fi lling the reservoir with oil, the lubricant must be poured
through the oil-fi ller screen
b) The oil-fi ller screen must be inspected after every 4 or 5 fi llings
and cleaned if necessary
c) If fi lling with a thin grease, due to the fact that SureFire PDI thin
grease models omit the fi lter screens, be sure the grease is fresh,
clean, and is not higher than 40,000 cp viscosity.
d) Do not use aggressive cleaners to clean the lubricator. Use only
mild cleaners or degreasers to clean the lubricator.
In the event of having to replace a pressure gauge, do
not remove the adapter from the top plate. Prevent the adapter from
rotating with one wrench as you remove the old gauge and install the
new gauge with a second wrench. Appropriate pipe thread sealant
applied to the male thread of the new gauge is recommended.
TroubleshootingPre-mature wear of the gear pump and the other moving parts is usu-
ally caused by dirty or contaminated lubricant.
Failure of the PDI injectors to deliver lubricant can be caused by an
incorrect commissioning sequence, resulting in either air or dirt being
trapped in the distribution network.
A permanently lit (red) LED, present on controller versions, is caused
either by the lubricant level in the reservoir being too low, or the
system not being able to build enough pressure to trigger the pressure
switch, or both. In either case, the red light (fault) can be cleared by
fi lling the reservoir and running the next pressure up/pressure relief
cycle successfully. This is usually done by pressing the manual lube
button.
If you have any questions and need technical assistance, our
Customer Service number is: 1-800-631-0168
ON/OFF Timer (optional)The ON/OFF Timer that came with your SureFire PDI Lubricator
automatically controls the lubricator to be ON for the time you set and
OFF for the time you set. Making the actual settings is covered below.
The Timer is a very simple device and as long as power is continuously
supplied, it continually cycles the motor of the lubricator ON and OFF
based on the time settings you choose.
WiringThe wiring diagram is shown on the next page. The Timer is wired to
the lubricator motor at the factory. For the oil version, ignore positions
7-8, and use all other positions for other lubricator functions as nec-
essary. For the grease version, ignore positions 8-9, and use all other
positions for other lubricator functions as necessary. Also, always
be sure to connect your power to terminals 1 and 2 on the Terminal
Block as shown, being careful to keep in place any jumpers that were
already installed at the factory.
If you have a 115VAC or 230VAC model, the
motor Duty Cycle is: S3 20%, which means the maximum continuous
“ON” time for any cycle is 3 minutes, and if the motor continuous
ON time is X, the required minimum OFF time for that same cycle is
5X. If you have a 24VDC model, there are no such maximum ON or
minimum OFF time requirements.
Time settingsMaking the ON and OFF settings on the Timer is very simple. The top
two dials on the front face control the ON time (0.1 seconds to 100
hours), and the bottom two dials control the OFF time (0.1 seconds
to 100 hours). For each pair of dials, the beige colored dial sets the
time range for the setting, and the blue colored dial actually makes
the setting.
For example, if you desired your ON time to be 8 seconds and your
OFF time to be 5 minutes, you would set the upper beige dial to be
“1-10” (seconds) and the upper blue dial to be 8, then you would set
the lower beige dial to be “1-10” (minutes) and the lower blue dial to
be 5.
It’s that simple. The Timer is working whenever power is supplied to
it. If the power is interrupted, the Timer completely stops. Once the
power is restored, the Timer begins again with whatever it’s current
ON time setting is. Also, to make lubricator adjustments easy, chang-
es to the ON and OFF time settings can be made while the timer is
running, and take effect at the beginning of the very next timed cycle.
Please be aware of the motor duty cycle restric-
tions as previously noted. Bijur recommends that the lubricator
be tested after making any time settings. This is to make sure the
settings are correct before the pump is left to run in an unattended
fashion.
10
Hydraulic Diagram
35022E R6-08/16
Timer - Wiring Diagram
11
Grease Version
Oil Version
Momentary "on" switch/ Interruptor momentáneo de "on"
Momentschalter “AN”/ Commutateur momentané de "on"
Level switch/ Interruptor llano / Füllstandschalter / Commutateur de niveau
Pressure switch / Interruptor de presión / Druckschalter / Mano-contact
2
1
(Customer option)/ (Opción del cliente)(Wahl des Kunden)/ (Option de client)
Ground / Tierra / Erde / La terre 0
10
9
8
7
4
5
6
3 A1 15 Y1
18 16 A2
115VAC (-)230VAC (-)24VDC (-)
115VAC (+)230VAC (+)24VDC (+)
(1) Jumper as shown(1) puente según lo demostrado(1) Überbrückungsdrähte (Verbindungsleiter) wie gezeigt(1) pullover comme montré
ENG
ESP
FR
DE
LED
MMotor
Wired atFactory
9
8
7
10.....30VDC (+)Output (+) 200mA
10.....30VDC (-)
(1) Jumper as shown(1) puente según lo demostrado(1) Überbrückungsdrähte (Verbindungsleiter) wie gezeigt(1) pullover comme montré
Level switch (N.O)Interruptor llano (N.O) Füllstandschalter (N.O)Commutateur de niveau (N.O)
ENG
ESP
FR
DE
ENG
ESP
FR
DE
Momentary "on" switch/ Interruptor momentáneo de "on"
Momentschalter “AN” / Commutateur momentané de "on"
11
10
Pressure switch/ Interruptor de presión/ Druckschalter/ Mano-contact
5
2
1
3
4
6
(Customer option)/ (Opción del cliente)(Wahl des Kunden)/ (Option de client)
Ground/ Tierra/ Erde/ La terre 0115VAC (+)230VAC (+)24VDC (+)
A1 15 Y1
18 16 A2
Brown/ Marrón/ Braun/ Brun
LED
Black/ Negro/ Schwarzes/ Noir
Blue/ Azul/ Blau/ Bleu
115VAC (-)230VAC (-)24VDC (-)
MotorWired atFactory
35022E R6-08/16
Spare Parts
12
Example SureFire PDI lubricator, 1.8 Liter Reservoir, for a PDI distribution network, standard version – for oil, Terminal Block Version (no timer, no controller), 230VAC incoming power.
SF 2 B N A D
How to Order
Controller typeA— Terminal block*B— ON/OFF timer (not available on 1.8 liter models)*C— Programmable controller/monitor
SF
VoltageB— 24 VDC, 2.4 ampsC— 115 VAC, 50/60 Hz, 2.2 ampsD— 230 VAC, 50/60 Hz, .95 ampsG— 100 VAC, 50/60 Hz, 2.0 ampsH— 200 VAC, 50/60 Hz, 1.0 amps
Reservoir capacity2— 1.8 Liter (Terlux plastic)3— 2.7 Liter (Terlux plastic)6— 6.0 Liter (Terlux plastic)12— 12.0 Liter (Painted steel)
Distribution systemB— Volumetric/PDI
OptionsN— Standard oil versionB— Standard grease version (grease level switch, no fill screen)A— Quick connect grease version (grease level switch and quick
connect style reservoir fill fitting for grease/no fill screen)C— Quick connect oil version (quick connect style reservoir fill
fitting for oil/no fill screenD— Standard oil version (2 position oil level switch)
Required wiring (if controller type C is selected)A— M12
*Controller type A & B are CE approved.Standard versions include: fl oat type reservoir low level switch, standard reservoir fi ll-cap screen, quick dump valve for PDIs, 450 psi pressure relief valve.
SureFire PDI MODEL NUMBERSF2BxxB SF2BxxC SF2BxxD
SF3BxxB SF3BxxC SF3BxxD
SF6BxxB SF6BxxC SF6BxxD
SF12BxxB SF12BxxC SF12BxxD
PART DESCRIPTION PART # PART # PART # PART #Reservoir
34794 34795 34796
Reservoir Assembly
35153Reservoir Gasket
Bolts
Washers
Reservoir O-Ring
Reservoir Clasp
Reservoir Clasp Plate
Reservoir Clasp Plate Screws
Reservoir Inlet Strainer Assembly (w/screws) 35150
Automotive Quick Connector Assembly - for grease applications (with O-Ring) 35151
Automotive Quick Connector Assembly - for oil applications (with O-Ring) 35152
Motor Cover
34791 34792 34793Motor Cover O-Ring
Motor Cover Screw
Level Switch (std. for oil)34797
39161-4793-1
34798Level Switch Stem
2 position Level Switch for oil 39161-4793-2
Level Switch for grease 23470
Pressure Gauge 23411
Pressure Switch 23472
On/Off Timer (optional) 35074
Motor (24 VDC) 27632
Motor (115/230 VAC) 34876
Motor Fan
35022E R6-08/16
Notes
35022E R6-08/16