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Single-Point Lubricators

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ㆍ The Single-Point Lubricator (SPL) is one of how to extend the life of bearing in manufacturing operation. This technology was introduced into the industry more than 50 years ago. SPL manufacturers have continuously introduced technological advances that have increased the life of bearings and the reliability of single-point lubricators. Original spring type lubricators (old compression grease cup) and Traditional gas charged lubricators (Chemical Reaction Type) are being replaced by New Generation of Electrochemical SPL. Pulsarlube-V, New Generation of Electrochemical, Automatic SPL, is designed to ensure a precise, predictable, and fresh supply of lubricant in a wide variety of industrial applications. Pulsarlube-V delivers self-contained (pre-packed) lubricant, under pressure, by means of a controlled electrochemical reaction that generates inert Nitrogen (N2) gas. Unlike traditional gas charged lubricators using combustible Hydrogen (H2) gas generation as the result of metal/acid reaction, Pulsarlube-V uses inert Nitrogen gas generation controlled by Microprocessor, which is similar to safety airbag technology widely used in modern vehicles. Pulsarlube-V unit has a variable dispensing rate from 1 to 12 month in a single unit. It is controlled by a microprocessor to ensure reliable and predictable lubricant delivery. Selectable rate of lubricant discharge is pre-programmed to meet the specification of bearing and equipment manufacturer. However, it is important to recognize that, regardless of gas type SPL unit selected, understanding general characteristics of Gas type SPL is needed.

Microprocessor inside User-friendly large LCD panel Simple operation Accurate/Reliable dispensing Six Variable dispensing rates Programmed logic circuit Auto purge cutout High Performance Lubricant

Operating Temp: -4 deg F ~ 140 deg F Max working pressure: 70psi Grease Capacity: 125cc, 250cc available 5 Standard grease: - PL1 : Multi Purpose - PL2 : Heavy Duty - PL3 : High Speed - PL4 : Food Grade - PL5 : High Temp * Special OEM fillings are available Anti-Explosive Certi grade: Ex ia I/II B T4

Access is hazardous or inconvenient Contamination is present Insufficient staff to guarantee lubrication   ㆍApplication

BALL & ROLLER BEARING BEARING SHAFT DIA MODE SETTING KLT500 KLT1000 105-120mm (4 1/8 - 4 3/4) - 1 MONTH 88 - 105mm (3 1/2 - 4 1/8) 1 MONTH 2 MONTHS 79 - 87mm (3 1/8 - 3 1/2) 2 MONTHS 3 MONTHS 63 - 78mm (2 1/2 - 3) 3 MONTHS 6 MONTHS 49 - 62mm (2 / 2 1/2) 6 MONTHS 12 MONTHS LESS 49mm(2) 12 MONTHS -

ㆍ The single point lubricator (SPL) is an automatic lubrication method widely used in modern manufacturing operation. Since their introduction more than 50 years ago, SPLs have undergone an extensive improvement process. Original spring type lubricators (old compression grease cup) were replaced by gas charged automatic lubricators, and battery-operated electromechanical lubricators are now replacing gas charged lubricators. These new SPLs offer more and more flexibility and reliability than their predecessors have. Here are the benefits and advantages of electromechanically operated SPL over traditional gas charged model. Pulsarlube M, one of the most sophisticated electromechanical SPL is designed to ensure reliable lubrication and cut lubrication cost by an advanced electronic control mechanism. It consists of a vertical feed pump, motor/gear set, and Microprocessor control system, which makes outstanding operating pressure available (20Kg-f/cm, 280psi, Typical). The lubricant is supplied in either 125cc or 250cc Pulsarlube grease pouches, which are replaceable along with an Pulsarlube battery pack. Pulsarlube M offers 6 optional dispensing rates from 1/2(Half) to 12(Twelve) months in a single unit.

Environment friendly Replaceable 125 or 250cc Grease pouch Customized Battery Pack (4.5V Alkaline) Easy Disposal User friendly Compact & Convenient Design Simple Operation Easy to read Large LCD Precise Lubrication - Easy Maintenance Cost competitive by multi use up to 8 pointsM (Using progressive divider blocks) Equipment friendly Precise and Reliable Lubrication High operating pressure (20Kg-f/cm, 280psi, Typical) Weight balanced Design Break-free 3/8 Brass fitting Wide Operating temp from -15 to 60 C (5 to 140˚F) Long-term reliability Appropriate Grease capacity

ㆍ Pulsarlube M is designed to last through many years of use. Over the years this can add up to substantial savings over the cost of manual lubrication and disposable one time use lubricators (mostly traditional gas charged products), while providing assurance of the highest quality of lubrication achievable. Pulsarlube M Service pack consists of grease pouch (125cc or 250cc), a battery pack (4.5V Alkaline), and disposable dust cover. Note : Pulsarlube M grease pouch and battery pack must always be changed at the same time. It is mandatory to ensure the reliable operation of unit.

ㆍ Pulsarlube M unit has excellent remote installation capability while traditional gas charged SPL suffers. Sometimes space restrictions will not allow a direct mount, angle mount or extension mount. In other circumstances, small fittings may not be suited to direct mounting due to thread weight limitations. It is also true there are many applications where access is hazardous or inconvenient, contamination or harsh environments present. Where this occurs, the use of remote mount is required. It is ALWAYS preferable to minimize the length of remote mounting. Pulsarlube M units should be mounted as close to the bearing point as possible. Remote Installation Kit consists of : 1. Pulsarlube M Unit (125 or 250cc) 2-4, 7. Mounting Bracket Assembly (Red circled) 5. Pipe connector (1/4 or 1/8M) 6. Tube Fittings (at both ends) 8. Nylon Tubing 6mm O.D. (Pre-filled)    * Refer to figure 1: Remote Installation of Pulsarlube M unit Multi-point Use For applications where many lube points existing in close proximity, Pulsarlube M can be used as automatic lubrication system of up to 8 points using progressive divider block. System Elements : 1. Pulsarlube M Unit (125 or 250cc) 2-6. Mounting Bracket Assembly (Red circled) 7. Pipe connector (1/4 or 1/8M) 8. Progressive Divider Block (4 to 8 ports) 9. Tube Fittings (at both ends) 10. Nylon Tubing 6mm O.D. (Pre-filled)    * Refer to figure 2: Multi-point use of Pulsarlube M unit using Progressive Divider Block (up to 8 ports) General Guideline 1. Keep in close proximity to lube points. 2. All elements should be pre-filled with same or compatible grease prior to installation. 3. Recommend using NLGI #1 grease for Multi point use. Typical Application ◎ Bearings Typical lube points for SPL are : 1. Taconite seal lubricant feed point 2. Housing, bearing &seal lubricant feed point 3. Bearing central lubricant feed point 4. Housing, bearing &seal lubricant feed point 5. Taconite seal lubricant feed point ◎ Electric Motors Electric motor lubrication is ideally suited to the SPL concept. However, electric motor bearings are lubricated less frequently than other bearing types. Over lubrication can result in greater problems than under lubrication. When Pulsarlube M unit is used on electric motors, ensure to follow manufacturers recommendation and that the bearing housing has a grease vent port. ◎ Pumps Pumps are one of the most common applications for SPL. They are subject to high water, chemical and corrosive material contamination. It is mandatory to maintain the constant flow of grease to seal out contaminants. If the seal can be effectively lubricated and purged by use of Pulsarlube M, the bearing failures and maintenance budget can be dramatically reduced. ◎ Conveyors Conveyors are widely used in cement, mining, food/beverage, and brewery industry. They are key elements to keep the high productivity and efficiency of manufacturing operation and subject to heavy dust/dirt, high water, chemical and other corrosive material contamination. Pulsarlube M unit is typically fitted to the bearing housings to lubricate bearings. The typical arrangement is ; One bearing and two seals per drive side housing. One bearing and one seal per non driven housing. (Housings are generally fitted with labyrinth or taconite type seals.) ◎ Agitators & Shafts Mainly, Agitators are for vertically mounted shafts to manufacturing, process and storage tanks. In the pulp and paper industry, they are for horizontally mounted shafts to drive paddles. Pulsarlube M units are fitted to the bearing housings to lubricate the bearings. Applications can be subject to high water, chemical and corrosive material contamination. Pulsarlube M provides a constant flow of grease to seal out contaminants. ◎ Journals(Plain Bearings) Plain bearings operate on a total loss system. They are typically used on auger shafts, gear support shafts or for power transmission. Applications can be subject to heavy load, high water, chemical and corrosive material contamination. When Pulsarlube M unit is used, please consider that Journal bearings usually require a higher lubricant volume than anti friction bearings of the same diameter. ◎ Sheaves Sheave applications are diverse and can include wire rope applications in Mining equipments, Elevators, Cranes, Hoists, and Cable belts etc. The working environment to these applications can have access restrictions and heavily contaminated environments. Pulsarlube M unit is used to lubricate sheave support bearings and also to apply lubricant to wire ropes.

Elements ㆍPumps ㆍElectric Motors ㆍConveyors ㆍBlowers ㆍAir Makeup units ㆍAir Conditioners ㆍFans ㆍCranes, Hoists, Loaders, Stackers ㆍEscalators, Elevators, Lifts ㆍAgitators ㆍFurnaces, Ovens ㆍCable Ways Industry ㆍIron/Steelmaking ㆍAutomotives ㆍMining (Open Pit/Underground) ㆍCement ㆍPetrochemical ㆍOil/Ore Refinery ㆍHeavy Industry ㆍShips ㆍElectronics/Semiconductor/LCD etc. ㆍFood/Beverage ㆍBrewery ㆍPulp/Paper ㆍTextile &All kinds of Production Equipments Non-manufacturing Applications ㆍAirports ㆍMetros ㆍBridges ㆍShipyards ㆍHotels, Shopping Malls ㆍHigh Story Buildings ㆍWaste Water Treatment Facilities ㆍSewage Treatment Facilities ㆍCity Water Treatment Facilities ㆍResorts Pulsarlube M units in the field   ㆍClean Room Lubrication in Semiconductor Plant (Taiwan)   ㆍGantry Loaders in Automatic Transmission Plant for Hyundai Motor Company-Remotely Installed   ㆍMotor Bearing in Cooling Tower (Amusement Park)   ㆍBlower Bearing in Cooling Tower (Amusement Park)   ㆍAir Makeup units-Remotely Installed   ㆍElectric Wire Making Plant

Understanding Backpressure The pressure generated is a response to resistance to flow presented to the unit. The most common back pressure causes are: Accumulation of deposits in bearings or passages ㆍSeals that will not permit flow ㆍLubricant feed ports between the unit and the bearing ㆍFittings with small feed passages ㆍLine pressure losses in remote mount installations While impractical to do anything about the design of the bearing arrangement, Pulsarlube M units should be mounted as close to the bearing point as possible. The shorter the distance the grease is required to travel, the less back pressure presented by the feed passage. IF IN DOUBT, test backpressure with grease gun connected to pressure gauge prior to installation. This testing also makes sure to fill the grease passage with same or compatible grease. Pulsarlube EX is a battery operated, single point lubricator with a replaceable 4.5V battery pack. The EX lubricator includes a powerful positive displacement pump designed to reliably lubricate your equipment. To install, simply mount the EX unit directly on the lubrication point, or remote install up to 10ft. The EX intermittently injects grease via a microprocessor chip to keep your rotating equipment precisely lubricated 24 hrs / day. PULASRLUBE EX 125cc(EX125) PULASRLUBE EX 250cc(EX250) The Pulsarlube EX design has been tested by the UL labs and meet the following requirements: UL79, Power-Operated pumps for Petroleum dispensing products, Eighth Edition ANSI/ISA-12.12.01-2000, Nonincendive Electrical equipment for use in Class I and II, Division 2 and Class III, Divisions 1 and 2 Hazardous locations. Rating Description CLASS I Flammable Gases, Vapors or Liquids 2 Groups-C, D DIVISION 2 Where ignitable concentrations of flammable gases, vapors and liquids are not likely to exist under normal operating conditions. GROUPS - C & D C (Ethylene), D (Propane) 2 Groups-C, D Operating Temperature Ranges Standard Battery 14 F ~ 122 F (-10 C~50 C) Lithium Battery -40F~140F (-40C~+60C) Max Operating Pressure 200psi (15 kg/cm) Installation Thread 3/8" NPT Adapter (available) Remote Installation Up to 10 feet (3 meters) Applications Single point lubrication Variable Timer Variable Timer Automatic Locking System: The Microprocessor locks the LCD within 30 seconds after having been programmed. A "Non - blinking lock I-Con is visible when the LCD is in "Lock - Mode". To unlock the LCD, press the "mode" button for 2 seconds until lock icon disappears. Warning - EXPLOSION HAZARD - DO NOT REMOVE OR REPLACE BATTERIES UNLESS UNIT HAS BEEN TURNED "OFF" BY PRESSING THE POWER BUTTON FOR 2 SECONDS, OR UNLESS AREA IS KNOW TO BE FREE OF IGNITABLE CONCENTRATIONS OF FLAMMABLE GASES OR VAPORS - IEC 60079-15 Electrical apparatus for explosive gas atmospheres - IEC 60529 Degrees of protection provided by enclosures - EN 50021/1999 Electrical apparatus for potentially explosion atmospheres type of protection "n" - UL 79 Power - Operated pumps for petroleum dispensing products. - ANSI/ISA-12.12.01-2000 Nonincendive electrical Equipment for use in class l and ll, Division 2 and class lll, Divisions 1 and 2 hazardous locations. Certification UL ATEX KTL Remark Rating ClassI Division 2 Groups-C, D EEx nL IIB T5 IP54 Ex nC IIB T5 IP54 - Gas groups D-C1 I Div 1/2 IIA IIA Propane Typical Gas D-C1 I Div 1/2 IIB IIB Ethylene Maximum Surface Temperature T6(85C) T5(100C) T5(100C) The skin temperature shall not exceed the minimum ignition temperature of the substances to be found in the hazardous location. The "T" code designations apply to motors and other types of electrical equipment subject to hazardous location classification. Enclosure protection indices - IP54 IP54 Protection against dust; -IP5X Dust penetration is not prevented altogether, but dust must not enter in sufficient quantities to prevent the equipment from operating satisfactorily, or to impair safety. Protection against water spray;-IPX4 Water splashes on to the enclosure from any direction must not have any harmful effects. Classification of hazardous locations CIDiv2 CIZone2(gas) Zone2(gas) Zone22(dust) - Ignitable concentrations not likely to exist under normal operations, or may exist for a short time only Certificate number E304815 - 2007-1167-Q1   ㆍ The ML500 consists of a vertical feed pump, motor/gear set, and Microprocessor control system, which delivers an outstanding operating pressure available of (280 psi, 20Kg-f/cm) The lubricant is supplied in 500cc Pulsarlube grease cartridges, which are replaceable along with a Pulsarlube battery pack. It offers 8 optional dispensing rates from (Half) to 24 months in a single unit. Operating temperature for Standard Battery: 14 F ~ 122 F (-10 C~50 C)    Lithium Battery: -40F~140F (-40C~+60C)   Normal operating pressure : 280psi (20kgf/cm)   Grease Capacity : 500cc   5 Standard greases available (OEM grease filling available)   Variable Settings Available : , 1, 2, 4, 6, 12, 18, 24 months   Default Setting : 1 Month   D.C. 4.5-Volt Lithium Battery   LCD locking system included   Can be used to lubricate multiple points (Up to 8 points).   500cc Diameter: 3.6 inches, Height: 9.5 inches, Weight: 2.65Lb(1.20Kg)   Each 500cc unit is individually packaged. (8 units per case; 23.00Lb/case)   B001: Standard Battery Pack              Three 1.5V Duracell Alkaline Batteries create one DC 4.5V Standard Battery Pack   LTB001: Lithium Battery (For low Temps, High Back Pressure & or 24 month settings)                  Three 1.5V Energizer Lithium Batteries create one DC 4.5V Standard Lithium Battery Pack.   P500: Disposable 500cc Grease pouch.   D500: 500cc Dust Cover (Transparent Plastic cover)   H500: 500cc Top Housing (Transparent Plastic Housing) Step1. Remove top lid from a 500cc cartridge. Step2. Remove plastic cartridge from the base of the lubricator. Step3. Insert your battery pack. Step4. Remove cap from 500cc grease pouch and place grease pouch into plastic cartridge before placing it on the base of the lubricator. Step5. Important! Make sure to purge grease manually until grease comes out of the tip of cartridge to eliminate air pocket. Step6. Wipe out the excess grease. Step7. Install the filled 500cc cartridge onto the base of the lubricator by turning clockwise. Step8. Install cartridge lid by turning clockwise. Step9. The assembly procedure has been completed. 1. Make sure the lubrication point is manually lubricated with a grease gun to ensure that the bearing has a clear passage way before installing your 500cc unit. It is recommended that this procedure be conducted using either the same or a compatible lubricant with what is contained in the grease cartridge of the Pulsarlube M 500cc unit 2. If any doubts exist in regards to a clear lubrication flow, test the backpressure of the bearing with a grease gun connected to a pressure gauge. Ensure that the break - off pressure is below 500 psi (approx. 35 kg-f/cm2: 34.5 bar). Note that it is always desirable to keep the constant delivery pressure as low as possible 3. Insert the Battery Pack into the battery compartment of the main unit. (Make sure that the battery is locked in place after insertion by turning the metal clip on top). Turn top housing clockwise until you hear the top housing "click". Open top housing cap and place the pointed open end of the grease pouch over the lubricators' top check valve and Turn Top housing cap until you hear the top housing "click" 4. Turn the Pulsarlube ML 500 unit ON by depressing the POWER button for 2 seconds. To confirm that the LCD is working, make sure that the Red LED blinks once as soon as you press the "power" button. The unit is working as long as the LCD displays information. 5. To test that the unit is functioning properly, simply follow the TEST MODE PROCEDURE: Press the POWER button first (for 2 seconds) to turn on unit, and then press the TEST button for 2 seconds. The unit will begin to start dispensing grease. The unit will operate continuously in Purge mode and go through an entire cycle of (approximately 2 min). To deactivate the TEST MODE FUNCTION, press the TEST button again. The unit will stop testing within the next 20 seconds. If the unit is malfunctioning or if you encounter any difficulty, please refer to the troubleshooting guide. 6. Depress the MODE button to set the dispensing rate. Each time the MODE button is depressed, the dispensing rate changes in ascending order i.e. 1▶2▶4▶6▶12▶18▶24▶ H. Note: (H = Half month.) Note : If you are unable to program a setting and a lock icon is displayed, press the mode button for           2 seconds until the lock icon disappears. Program your lubricator. The unit will automatically lock           60 seconds after you stop pressing any of the 3 programming buttons. 7. Remove the grease nipple on lube point. Wrap some Teflon tape on the lubricator tip and install a 3/8" female NPT or BSP adaptor to bottom of unit. The other end of the adaptor must have the correct size of your zirk fitting. Make sure that the unit is snugly tightened to adaptor. The 3/8" brass thread of the unit is vibration proof. In other words, it ensures that the fitting will not snap off at the tip even under severe vibration or shock loads. 8. For installations that involve extreme vibration, excessive heat, or service locations that are considered hazardous, we recommend you use a remote mounting bracket (clamping device) and " line no longer than 10ft. (if possible) that is available at Pulsarlube. IMPORTANT : Please make sure that the " line is pre-filled, prior to installation. Remote installation of                       over 10ft will reduce the ability of the unit to dispense against elevated backpressure.   Automatic Locking System: The Microprocessor locks the LCD within 60 seconds after having been programmed. A "Non - blinking lock I-Con is visible when the LCD is in "Lock - Mode". To unlock the LCD, press the "mode" button for 2 seconds until lock icon disappears.   Low Battery Sensing Capability: A Red LED warning light next to the test mode button blinks every second when low battery exists.   Daily Dispensing Rate Display: After selecting a monthly setting, the daily dispensing rate will display as shown on chart below. The LCD will automatically lock 60 seconds after the unit has been programmed. The LCD will then display days until end of cycle. Setting Daily Dispensing Rate LCD Display 33.3 1 16.6 2 8.3 3 4.2 6 2.8 12 1.4 18 0.9 24 0.7   Pump dispensing cycles. No Mode Settings Cycles/time intervals (Cycles/day) 1 (H month) 1 cycle / 15 min (96 cycles/day) 2 1 1 cycle / 30 min (48 cycles/day) 3 2 1 cycle / 1hr (24 cycles/day) 4 4 1 cycle / 2hrs (12 cycles/day) 5 6 1 cycle / 3hrs (8 cycles/day) 6 12 1cycle / 6hrs (4 cycles/day) 7 18 1cycle / 9hrs (2.66 cycles/day) 8 24 1cycle / 12hrs (2 cycles/day) 9 TEST Function Press TEST button for 2 seconds   Grease dispensing rate guide for 125cc, 250cc & 500cc lubricators. Bearing Shaft Dia. 125CC Grease Volume (CC/Day) 250CC Grease Volume (CC/Day) 500CC Grease Volume (CC/Day) 230-330mm (9" - 13") N/A - N/A - H Month 33.3 166-229mm (6 1/2 - 9) N/A - H Month 16.6 1 Month 16.6 102 - 165mm (4 - 6 1/2) 1/2 Month 8.3 1 Month 8.3 2 Month 8.3 90 - 101mm (3 1/2 - 4) 1 Month 4.2 2 Month 4.2 4 Month 4.2 77 - 89mm (3 - 3 1/2") 2 Month 2.1 3 Month 2.8 6 Month 2.8 65 - 76mm (2 1/2 - 3) 3 Month 1.4 6 Month 1.4 12 Month 1.4 18 Month 0.9 51 - 64mm (2 ~ 2 1/2) 6 Month 0.7 12 Month 0.7 24 Month 0.7 25 - 50mm (1 ~ 2) 12 Month 0.3 N/A - N/A -   Pulsarlube M 500 cc unit Battery Selection Guide No Standard Alkaline Battery Lithium Battery Temperature 14F~122F (-10C~+50C) -40F~140F (-40C~+60C) Back Pressure 280psi or less Constant Back Pressure Handles > Than 280psi Constant Back Pressure. Divider Block N/A Up to 8 points Distance 10ft or less for remote installations Handles greater than 10ft/line for remote NO PART NO PART NAME DESCRIPTION QTY IMAGE 1 B011 Divider Block Divider Block Grease Type U-4R 1 2 B012 Divider Block Grease Type U-6