This document describes the iSHAN Centralized Lubrication Systems, specifically the YGL-G and YGL-GA models, which are designed for automatic grease lubrication. These systems are used to lubricate various mechanical components such as ball bearings, flat slideways, circular slideways, linear guides, cams, gears, chains, lathes, mills, presses, planners, grinders, and other machinery.
Function Description:
The iSHAN Centralized Lubrication Systems automatically supply grease to multiple lubrication points from a central reservoir. The YGL-G model is an electric automatic grease lubricator, while the YGL-GA model is a microcomputer-controlled electric automatic grease lubricator. Both models are designed to ensure consistent and timely lubrication, reducing manual effort and improving the lifespan of machinery.
The system's operation is controlled by setting intermittent and lubrication times. The YGL-G model uses a timer control and PLC control, while the YGL-GA model offers more advanced microcomputer control with a digital display for settings. The intermittent time (interval between lubrication cycles) and lubrication time (duration of grease discharge) can be adjusted from 1 to 999 units (second/minute/hour/count). For the YGL-GA, the default setting for the unit of intermittent time is minutes, and for lubrication time, it is seconds. The operator can adjust these settings based on the specific lubrication requirements of the machinery.
The system includes a pressure relief valve to prevent injury, death, or property damage. It also features various indicators and alarms to alert the user to operational issues. These include a yellow indicator for lubrication, a green indicator for intermittent time, and a red indicator for alarms (e.g., low oil level, pressure issues, or abnormal distributor action).
Important Technical Specifications:
- Models:
- YGL-G080 (standard)
- YGL-G120 (standard)
- YGL-G200 (standard)
- YGL-GA080 (standard)
- YGL-GA120 (standard)
- YGL-GA200 (standard)
- Voltage: AC220V, 110V, 380V, or DC24V.
- Permitted Lubricant: YGL-G08/120/200 apply No.00/000 grease. YGL-G120/200 with spring-loaded follower plate apply No.00/000/1 grease. Only new lubricant should be used.
- Max. Discharge: 16 ml/min.
- Max. Output Pressure: 100 kgf/cm².
- Output Thread: Rp1/4.
- Reservoir Capacity:
- YGL-G080/GA080: 800 ml
- YGL-G120/GA120: 1200 ml
- YGL-G200/GA200: 2000 ml
- Intermittent Time/Lubrication Time Settings (YGL-GA): Adjustable from 1 to 999 units. Default unit for intermittent time is minutes, and for lubrication time is seconds.
- Piston Detector Function (YGL-GA):
- P-0: 0-1 (effective/ineffective)
- P-1: 1-999 (permissible max. cycle)
- P-2: 1-999 (permissible min. cycle)
Usage Features:
- Installation: The unit should be installed in an appropriate location, with mounting dimensions observed. The lubrication unit is attached to the intended mounting location using appropriate fastening materials. The installation location should be spaced between 0.6m to 1.7m above the ground.
- Filling: Lubricant should be filled using a grease gun through the grease nozzle. New oil with a permitted range of grease grade (No.00/000 or No.0,1 grease with spring-loaded follower plate) must be used. Never refill with used oil.
- Lubrication Line Connection: Remove the plug from the lubrication unit first. Use thread seal tape attached to the adapter. Solderless tube connections (double tapered sleeves) can be used. The tube must go through compressed bushing and double tapered sleeve. To avoid any leaking during running service time, it should be observed up to 1mm distance between the tube end to the double sleeve. Insert tube end into counterbored port and tighten the compressed bushing.
- Wiring and Alarm: Wiring must comply with the electrical circuit diagram. A fuse between the power supply and the product is strongly recommended. The electrical circuit diagram of the lubrication unit is affixed inside the unit and can be accessed by removing the cap. Proper wiring is crucial to prevent serious injury, death, or property damage.
- Deaerating: The lubricant may contain air bubbles, which can affect performance. The system is designed to deaerate the lubricant. This process involves unscrewing the vent bolt until bubble-free lubricant escapes, and then filling longer pipe sections before connecting the system to the lubricating point.
- Control Panel (YGL-GA): The control panel features a digital display for intermittent and lubrication times, along with buttons for increasing/decreasing these values. It also has indicator lights for lubrication (yellow), intermittent time (green), and alarms (red). A RES (feed pushbutton) is used to reset the system.
- Operating Mode Setting (YGL-GA): Only authorized personnel can change the default settings.
- Progressive Distributor with Piston Detector (YGL-GA): A cycle switch (piston detector) can be installed to monitor the distributor functions. The display shows P-0 on the upper screen and 00* on the lower screen. Pressing the lubrication increase/decrease button changes the function code. Pressing the intermittent increase/decrease button changes the value listed below the chart. Pressing the RES button returns to normal running operation.
- Indicator Lamp and Alarm (YGL-GA):
- Level Switch: Indicator lamp is on when the contact is closed and alarm activates. When the contact is open, the indicator lamp is off and the alarm stops.
- Cycle Switch: Indicator lamp is on when the number of cycles is not in the range of the user's setting after discharging finished.
- Standard Model: Indicator lamp of pressure is on when the contact of pressure switch closed after pumping operation complete. Indicator lamp of pressure is off and the contact of pressure switch open after pumping operation complete.
- Alarm Instruction: Alarms include low lubricant level (E-O on display), pressure issues (E-P on display), and piston detector cycle counts out of setting value (E-A on display).
Maintenance Features:
- General Maintenance: Regular maintenance is crucial for the system's longevity and performance. This includes checking the lubricant level, ensuring proper wiring, and addressing any faults promptly.
- Refilling Lubricant: Always keep the lubricant level between HIGH mark and LOW mark. If the lubricant level falls below the LOW mark, the lubrication unit will send an alarm signal to the control unit of the machine. Remove the cap and refill with new clean lubricant. Never use used lubricant.
- Troubleshooting: The manual provides a comprehensive troubleshooting guide for common faults:
- Motor Failure: Return to iSHAN or iSHAN agent.
- No Lubricant: Refill lubricant.
- Air in the Centralized Lubrication System: Vent the centralized lubrication system.
- Motor Runs but Doesn't Feed Oil: Disconnect the pipe from the output adapter to visualize check if discharging from the lubrication unit. If so, check for blocked or broken pipes in the delivery pipe and repair. Remove lubricant from the entire system and dispose of lubricant in the proper manner; fill system with suitable lubricant.
- Insufficient Oil Delivery: Remove lubricant from the entire system and dispose of lubricant in the proper manner; fill system with suitable lubricant.
- Leaking: To avoid any leaking during running service time, it should be observed up to 1mm distance between the tube end to the double sleeve. Recommend metal pipe or high-pressure plastic pipe.
- Electric Leakage: If water comes in contact with electric wire or earth faults in electrical appliances, indicate with remark where occurred and then return to iSHAN for repair.
- Warranty: iSHAN warrants that products will be repaired or replaced if found defective in material or workmanship within one year from the date of original purchase. The warranty claim is considered invalid if the product is not complete or was disassembled or failed due to manual or damage caused by an act of God. Any return must consult with iSHAN and obtain iSHAN's approval before action.
- Safety Precautions: Before installing, read the manual for the correct connection of the power. To prevent chance of serious injury, death or property damage, disconnect the product from main power supply before working on it. Comply with the specifications on the rating plate of the motor or the electrical components. iSHAN products must only be used for their intended purpose. The described product is for supplying centralized lubrication systems with lubricant and is intended for use in centralized lubrication systems. Any other use of this product constitutes improper use.
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