Workshop manual

TWIN greasing system

EM1701D1.DOC

THE GINA
TWIN GREASING SYSTEM

INTRODUCTION

The GINA (Groeneveld tester for INstallation and Analysis) is a programming and read-out device for the digital control unit of the TWIN greasing system.
In the description that follows all screens of the GINA are dealt with in the order in which they have been
placed in its menu system. Toget aquainted with the menu system and the features the GINA offers, we advise
you to follow the sequence as presented, if only once. In practise there is, of course, no reason whatsoever for
such a rigid and time consuming approach. Normally, you would go directly to the screen that contains the information you want to view or the settings you wish to change.
The read-outs and setting have been grouped in three menus:
main menu
parameters timer
diagnosis menu.

You can access each of these menus by pressing MAIN , PARAMETERS or DIAGNOSIS on the keypad op the GINA.
You can do so at any time, regardless of the screen currently shown on the display.
Some screens just show information. You cannot change anything in those screens. Other screens allow you to
change parameters or the status of a particular input or output. You can recognise those screen by the blinking
cursor that appears on them (with the exception of the system configuration and error-logging-reset screens).
A number of screens show the current time in their top-right corner. In the screens, as reproduced in this manual, this is indicated by hh:mm:ss. Values are usually denoted to by a number of x-signs, with one x for every
possible digit in the number.

PREPARATIONS

2.1

Control pad

Besides a 4-line display, the GINA features they following keys:

key

function

POWER ON/OFF

To turn the GINA on or off (toggle).

F1
0

... F4 (softkeys)

To make a particular choice in a menu.

... 9

To enter numerical data.

MAIN

To call the main menu (to view miscellaneous information)

PARAMETERS

To call the parameter timer menu (to view and enter parameter data)

DIAGNOSIS

To call the diagnosis menu (to view various system data)

NEXT

To go to the next screen in the menu system.

ENTER

To confirm a setting you have changed or entered.

Operation

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TWIN greasing system
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2.2

Connecting the GINA

The supply voltage of the control unit to be read or programmed must be available (from the vehicle or an external power supply, if need be).
Connect the GINA with the control unit with the supplied interconnection cable.
Remark:
While the GINA is connected to the control unit, the mode-selection switch on the dashboard (if present) of the
vehicle cannot be used to change the greasing systems operating mode.

2.3

Switching on

The GINA can be switched-on after,

1. the GINA has been connected with the control unit, and
2. the power supply has been available to the control unit for at
least 8 seconds.
Press POWER ON/OFF and wait about 5 seconds for the GINA to initialise itself.


 
 !
"

You can access the main , parameters timer and diagnosis menus by
pressing respectively MAIN , PARAMETERS or DIAGNOSIS .
Each of those menus are described separately in the chapters 5, 6
and 8.

This message appears in the GINA is unable to communicate with

the control unit.



  

 

This can be caused by:

Bad connection (wire in cable broken or a bad connector)

GINA switched on to quickly.
Supply voltage too low

Always try to alleviate the problem by turning the GINA off and
then on again, or by pressing one of the softkeys ( F1 ... F4 ).

This message appears if the control unit is not supported by this

GINA. You need another GINA to access this control unit.

B - 16

  

Operation

Workshop manual
TWIN greasing system
EM1701D1.DOC

3
3.1

THE MENU SYSTEM

Main menu

The main menu contains various data about the GINA and the control unit that is connected. You change only some of the data.
Press MAIN

 

Press F1 (info).

"%

The screen shows the identification number of the person who

most recently connected a GINA to this control unit. Attention:
This number is overwritten, when the GINA is switched-off.
Press F2 (d-ac).

The screen shows the date and time at which a GINA has, most recently, been connected with this control unit. Attention: this date
and time are updated when you switch-off the GINA.
Press F3 (u-ch).

The screen shows the identification number of the person who,

most recently, changed any settings of this control unit. Attention:
This number will be overwritten when you switch-off the GINA,
provided you have changed at least one setting.

",

#% 





##' ((((((
)*
#
+*
#
)*#$

+*#$


",-+
.

##
((*((*(( (('((
)*
#
+*
#
)*#$
+*#$




 #$
%&' ((((((
)*
#
+*
#
)*#$

+*#$

Press F4 (d-ch).

The screen shows the date and time at which the settings of this
control unit were most recently changed. Attention: This time and
date will be overwritten when you switch-off the GINA, provided
you have changed at least one setting.


",-+
.
 #$%&
((*((*(( (('((
)*
#
+*
#
)*#$
+*#$

Press NEXT .

The display shows the version number of the software in the

GINA.
Press F2 (p-ui)

Operation


 !
 /"%
0& )%" ' ((((
0*
0*)"

##

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TWIN greasing system
EM1701D1.DOC

The display shows the identification number of the registered user

of this GINA.
Press F3 . (access)

The display shows the access level for all control units that are
supported by this GINA. (you cannot change access levels).

Press NEXT

The screen shows the version number of the software in the GINA.


)
0& )%" ' ((((
0*
0*)"

##



) $"
"% /
((( 1+/"# (2

+3

+4


Press NEXT .


 !
 /"%
0& )%" ' ((((
0*
0*)"

##

The screen shows the version number of the display texts in the
software of this GINA.


 /' (((((((((



Press MAIN to return to the main menu.

Press F2 (time).

 
"%

The screen shows the hours of the current day and time. You can
change this setting with the numeric keys. Confirm the new setting
with ENTER .
Press F2 (min).

The display shows the minutes of the current date and time. You
can change this setting with the numeric keys. Confirm the new
setting with ENTER . As soon as you press ENTER , the seconds will
start running at zero.

",

#% 


%  $)
((
$
,"%


%  ,"%) 
((
$
,"%

Press NEXT .

The display shows the day of the month of the current day and
time. You cannot change this.
Press F2 (mnth).

B - 18


%  +

((
+

,% $



Operation

Workshop manual
TWIN greasing system
EM1701D1.DOC

The display shows the month of the current day and time. You
cannot change this.
Press F3 (year).

The display shows the year of the current date and time. You cannot change this.
Press MAIN to return to the main menu.


%  ,% $
((
+

,% $





%  

((
+

,% $




 
Press F3 (contr).

"%

",

#% 

The contrast of the display may be increased or decreased in this

screen.

 

Press F1 (-) to lower the contrast or F4 (+) to raise it. Press the keys
until you are satisfied with the contrast setting.

+5) #% 

*

3.2

Parameters timer

The parameters timer menu contains the parameter settings for the
greasing cycle. You can view and/or change these parameters (provided you have the correct access level.
Press PARAMETERS .
The display shows the duration (in minutes) of the greasing cycle
as set for the heavy-duty mode. You can change the value with the
numeric keys. The cursor indicates the digit about to be changed,
and automatically moves along one digit when a digit is entered.

 
$
/*+)  ## 
(((( 1,"%) 2
$+#
%+#
+#

#,

If the value shown is OK: press ENTER to confirm it. The cursor
then disappears from the display.
Press F2 (ndcy).

Operation

B - 19

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TWIN greasing system
EM1701D1.DOC

The display shows the duration (in minutes) of the greasing cycle
in normal-duty mode.
If necessary, change this value (confirm with

ENTER ).

 
%,
*+)  ## 
(((( 1,"%) 2
$+#
%+#
+#

#,

 
!*+)  ## 
(((( 1,"%) 2
$+#
%+#
+#

#,

Press F3 (ldcy).

The display shows the duration of the greasing cycle (in minutes)
in light-duty mode.
If necessary, change this value (confirm with

ENTER ).

Press F4 (cms).

The display shows which operating mode is currently active:

(disabled) The operating mode cannot be set by the driver or
operator. The normal-duty mode is used by default.
1 heavy-duty mode
(short greasing cycle)
2 normal-duty mode (normal greasing cycle)
3 light-duty mode
(long greasing cycle)
0

 
##  ,+  #
(' 78+" 98$+ :8%+ ;8 +
$+#
%+#
+#
#,

Press NEXT .

The display shows the maximum duration of the pump phase of a

greasing cycle (in minutes).
If necessary, change this value (confirm with

ENTER ).

 
,
(",), 0),0 ",
((( 1,"%) 2
,0
/,
%

<#+#

Press F2 (vmf).

The display shows the factor with which the actual duration of a
 
pump phase is to be multiplied to calculate the required duration of
/% ,) "0  
# 
the pressure-relief phase
((( 1=972
The value shown on the display must be divided by 10 to obtain the actual factor.

,0

If necessary, change this value (confirm with

/,

<#+#

ENTER ).

Press F3 (noa).

B - 20

Operation

Workshop manual
TWIN greasing system
EM1701D1.DOC

The display shows the maximum number of consecutive greasing

cycles, in which the required greasing pressure was not attained,
that can be allowed (after which the pump and 5/2 valve must be
disabled to prevent damage, and the signal light continuously lit)
The incorrectly executed greasing cycles that are counted are:
cycle A and B (ABABA or BABAB), or
cycle A or B (AAAAA or BBBBB).

 
%),< 
,0 
(((
,0
/,
%

<#+#

If necessary, change this value (confirm with ENTER ).

Press F4 (bcdc).

The display shows the number of times the blinking-code for the
operating mode will be repeated by the signal light when the contact is switched-on.
If necessary, change this value (confirm with

3.3

ENTER ).

 
< "% #+ +)  ## 
(
,0
/,
%

<#+#

Diagnosis menu

The diagnosis menu contains various bits of information about the

greasing systems status, like error messages and the status of the
inputs and outputs of the control unit.
Press DIAGNOSIS .
Press F1 (err).


 



=

/


In the displays that follow, various counters are shown. These

counters register the number times particular faults occurred in the
system since it was installed.



  

Press F1 (tote).

The display shows the number of greasing cycles in primary grease

line A, during which the grease-pressure switch was not activated
(low to high).
Press F2 (npcb).

The display shows the number of greasing cycles in primary grease

line B, during which the grease-pressure switch was not activated
(low to high).
Press F3 (pbcy).

Operation

0%+

"%

,"

 
% 0 #$%& "% 
(((((
%0#

%0#<
0<#

 
% 0 #$%& "% >
(((((
%0#

%0#<
0<#

B - 21

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TWIN greasing system
EM1701D1.DOC

The display shows the number of times the contact of the greasepressure switch was still closed at the start of a pump phase.
Press NEXT .

The display shows the number of times a short-circuit was detected

in the pump motor circuit.
Press F2 (pol).

The display shows the number of times an interruption was detected in the pump motor circuit.
Press F3 (lsc).

The display shows the number of times a short-circuit was detected

in the signal light circuit.
Press F4 (lol).

The display shows the number of times an interruption was detected in the signal light circuit.
Press NEXT .

The display shows the number of times a short-circuit was detected

in the circuit of the 5/2 solenoid valve.
Press F2 (vol).

The display shows the total number of greasing cycles in which an

interruption was detected in the 5/2 solenoid valve circuit.
Press F3 (lowl).

The display shows the total number of greasing cycles in which the
minimum-level switch has reported a low grease level in the reservoir
Press F4 (eres).

B - 22

 
0 < ## 
(((((
%0#

%0#<
0<#
 
0),0 $ #"#)"
(((((
0#
0
#

 
0),0 0% 
+
(((((
0#
0

#

 

,0 $ #"#)"
(((((
0#
0
#

 

,0 0% 
+
(((((
0#
0

#

 
/
/ $ #"#)"
(((((
/#
/
!



 
/
/ 0% 
+
(((((
/#
/
!



 
! /
(((((
/#
/



Operation

Workshop manual
TWIN greasing system
EM1701D1.DOC

The display shows the total number or greasing cycles in which the
minimum-level switch has reported that the reservoir needs to be
refilled, and the maximum pump time was reached (because the
required grease pressure was not reached, as signalled by the
grease pressure switch).

 
,0  /"
(((((
/#
/
!



Press NEXT .

Press F2 (pnde).
In the displays that follow, the numbers of pending errors are
shown. These are currently active failures. The counters are incremented each time the failure occurs, but set to zero if the failure
did not occur during a subsequent greasing cycle.



  
 

0%+

,"

After the last display of the pending errors has been shown: Press
NEXT .
Press F3 (meis).
In the displays that follow, the maximum number of times particular failures have occurred in consecutive greasing cycles are
shown. The values are overwritten only it a new sequence of failures is larger than the preceding one (for that particular fault).
After the last display with 'maximum errors in succession has been
shown: Press NEXT .

Press NEXT .Which brings you back to the diagnosis menu.


 


Press F2 (I/O).



Operation

=

/


"%

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TWIN greasing system
EM1701D1.DOC

The display shows the current status of the greasing system:

0
1
2
3

auto
man
sngl
mult

the system is in its normal operating condition.

the system is controlled by hand (with the GINA).
the system is busy performing a single-cycle test.
the system is busy performing a multiple-cycle test.

=
", ,+' 7
) 
(' 98,
% :8%& ;8,)
,+

You can change the current status of the system by pressing either
0 , 1 , 2 or 3 and confirming that action with ENTER .
Note1: You cannot initiate a test cycle if the system is busy with a
pump phase.
Note 2: The status will automatically return to 0 (auto) when the
contact is switched-off.
Press NEXT .

This is the first I/O-display. The status of the various inputs and
outputs of the control unit are shown.
An input or output can be either low (0) or high (1) (False or
True).
pump
vlve
lamp
press

the electric motor of the pump runs.

the 5/2 solenoid valve is actuated.
the signal light is lit
the contact of the grease-pressure switch is closed.

=
= 9
(
(
0),0
/ /

,0

(
0

The status of the outputs can be changed by pressing F1 , F2 or F3 .

This either starts or stops the pump, activates or deactivates the
solenoid valve, or lights or extinguishes the signal light.
Note: You can only do this if you have set the systems status to
1 (manual) in the previous display.
Press NEXT .

B - 24

Operation

Workshop manual
TWIN greasing system
EM1701D1.DOC

This is the second I/O-display:

An input or output can be either low (0) or high (1) (False or
True).
pol
vol
lol
gbsw

=
= :
(
(
0
/

(
&<!

(pump open load) interruption in the pump circuit. This indicator is valid only when the pump in not running.
(valve open load) interruption in the solenoid valve circuit.
This indicator is valid only when the valve is not actuated.
(lamp open load) interruption in the signal light circuit.
This indicator is valid only if the light is not lit.
(gear box switch) The supply voltage to the greasing system has been enabled via an extra switch (to start the
greasing program).

Press NEXT .

This is the third I/O-display:

An input or output can be either low (0) or high (1) (False or
True).
lowl
test
spr

=
= ;
(
(
!


(
0

(
0

=
= ?
(
(
0#
/#

(
#

(
0

(low level) the contact of the minimum-level switch in the

reservoir is closed.
the test pushbutton on the pump unit is being depressed.
(spare)

Press NEXT .

This is the fourth I/O-display:

An input or output can be either low (0) or high (1) (False or
True).
psc
vsc
lsc
spr

(pump short circuit) short-circuit in the pump circuit.

(valve short circuit) short-circuit in the solenoid valve circuit.
(lamp short circuit) short circuit in the signal light circuit.
(spare).

Operation

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TWIN greasing system
EM1701D1.DOC

Press DIAGNOSIS .


 


Press F3 (var).



The display shows the remaining time (of the current greasing cycle) to the pump phase of the next greasing cycle.
Press F2 (pintv).

The display shows in which phase of the greasing cycle the greasing system currently is.
2
3
4
29
32
33
34
59

pump phase, cycle A

pressure-retaining phase, cycle A
pressure-relieving phase, cycle A
pause phase, cycle, A
pump phase, cycle B
pressure-retaining phase, cycle B
pressure-relieving phase, cycle B
pause phase, cycle, B

=

/


"%

>
$$',,'
,
"%"%& ##  ",
((((( 1,"%) 2
#
0"% /
0

>
$$',,'
0&
, "% /

((
#
0"% /
0

Press F3 (lpt).

The display shows the duration of the last pump phase (in seconds).
Press NEXT .

>
$$',,'

 0),0"%& ",
((((( 1#%+2
#
0"% /
0

Press F4 (tinfo).


 



=

/


"%

Press F1 (pdif).



0+"
The display shows the part number of this control unit.
Press F2 (srno).

B - 26

$"

 
0
 %),<
(((((
0%
%
"/

Operation

Workshop manual
TWIN greasing system
EM1701D1.DOC

The display shows the serial number of this control unit.

Press F3 (tive).

The display shows the configuration (a number) of the control unit,

concerning the software, the hardware and the components used.
Press NEXT .

Press F2 (hist).

 
"
%),<
(((((((((((
0%
%
"/
 
", /"%
(((
0%
%
"/



0+"

The display shows the number of running hours, so far, of the

pump.
Press F2 (tot).

The display shows the number of hours the control unit has been
up and running. (the time the supply voltage was present on pin 3
of the connector of the control unit).
Press F3 (tcy).

The display shows the number of greasing cycles the system has
performed since it was installed.
Press F4 (teewr).

The display shows the number of times the EEPROM in the control unit was overwritten (data/parameters changed and stored).

$"

@A

0),0"%& ",
(((((( 1$)2
0

#

!

@A

0
"%& ",
(((((( 1$)2
0

#
!

@A

## 
((((((((((
0


#

@A

 !" 
((((((((
0

#

!

!

All displays have now been shown. If you are satisfied with all
settings, you can switch off the GINA.
Press POWER ON/OFF .
Remove the interconnection cable from the GINA and the control
unit.

Operation

B - 27

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TWIN greasing system
EM1701D1.DOC

4
4.1

STRUCTURE OF THE MENU SYSTEM

Abbreviations

minus (decrease display contrast)

plus (increase display contrast)

access

authorisation level

bcdc

blink code duty cycle

(the number of times the start-up blink code will be repeated)

cms
contr

cycle mode select

contrast

(selection of the operating mode)

(setting the display contrast)

d-ac
d-ch
day
eres
err

time & date, last access

time & date, last change
day (of the week)
empty reservoir
errors

gbsw

gear box switch

(extra program activation switch)

hdcy
hist
hrs

heavy-duty cycle
historic (data)
hours (time)

(operating mode with short greasing cycle)

I/O
info
inp/outp

inputs/outputs
information
inputs/outputs

(about the GINA)

lamp
ldcy
lol
lowl
lpt
lsc

lamp (signal light)

low-duty cycle
lamp open load
low level switch
last pumping time
lamp short circuit

(operating mode with long greasing cycle)

(interruption in signal light circuit)
(minimum-level switch)
(duration of last pump phase)

meis
min
mode
month
mpt

maximum number of errors in succession

minutes (time setting)
mode (operating mode)
month (date)
maximum pumping time

ndcy
noa
npca
npcb

normal-duty cycle
number of attempts
no pressure change line A
no pressure change line B

(operating mode with greasing cycle of default duration)

(until pump and 5/2 valve are disengaged by the control unit)

p-s
p-ui

software-version programmer unit

user id programmer unit

(GINA)
(GINA)

B - 28

(maximum duration of the pump phase)

Operation

Workshop manual
TWIN greasing system
EM1701D1.DOC

pbcy
pintv
pnde
pol
press
prno
psc
pump

pressure before cycle

program interval
pending errors
pump open load
pressure switch
part number
pump short circuit
pump

(pressure not relieved before next pump cycle)

(status of current greasing cycle)
(active malfunctions)
(interruption in pump circuit)
(grease-pressure switch)
(part number of the control unit)
(short circuit in the pump circuit)

rct

remaining cycle time

(time until the next pump phase)

spr
srno

spare
serial number

tcy
teewr
test
text version
time
tinfo
tive
tote
tot
put

total cycles
total EEPROM writes
test switch
text version software GINA
time
timer information
timer version
total errors
total operating time
total pumping time

(total number of greasing cycles performed so far)

(total number of times parameters or settings have been changed)
(test pushbutton on the pump unit)
(the version number of the display texts programmed in the GINA
(the current time)
(information about the control unit)
(information about the configuration of the control unit)
(the total number of malfunctions detected)
(the total time that the system has, so far, been in operation)
(The sum of all pump phases, so far).

u-ac
u-ch

user id, last access

user id, last change

(Identification of the user who last accessed this control unit)

(identification of the user who last changed settings)

var
vlve
vmf
vol
vsc

variables
valve
venting multiply factor
valve open load
valve short circuit

(5/2 solenoid valve)

(multiplication factor to calculate the relief-phase)
(interruption in the solenoid valve circuit)
(short-circuit in the solenoid valve circuit)

year

year

Operation

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EM1701D1.DOC

4.2

The main menu

MAIN

4.3

info

time

contr

u-ac
d-ac
u-ch
d-ch

hrs
min

p-s
p-ui
acces

day
mnth
year

=

NEXT

The parameters menu

PARAMETERS
hdcy
ndcy
ldcy
cms
mpt
vmf
noa
bcdc

B - 30

=

NEXT

Operation

Workshop manual
TWIN greasing system
EM1701D1.DOC

4.4

The diagnosis menu

DIAGNOSIS
var

I/O

err

tinfo

mode

rct
pintv
lpt

pump
vlve
lamp
press

pdiff

pol
vol
lol
gbsw

prno
srno
tive

hist

tcy
tol
tpt
teewr

lowl
test
spr
spr
psc
vsc
lsc
spr

tote

pnde

meis

npca
npcb
pbcy

pending
errors

error
counters

psc
pol
lsc
lol

=

NEXT

vsc
vol
lowl
eres
Operation

B - 31

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EM1701D1.DOC

B - 32

Operation