19_670864alemitecls1000

Service GuideCentralized Lubrication System (CLS) Controller The Alemite solid state CLS 1000 is a multi-use controller with the ability to be incorporated into various types of centralized lubrication systems. It can be used with multiple AC and DC voltages in systems requiring a system feedback principle (cycle or pressure switch) or in a timed on/off mode. The lubrication scheduled intervals can be initiated by time, machine cycle/strokes or manual run and programmed to provide a pre-lubrication cycle or reset to zero with no pre-lube at startup. It can be used with pneumatic, motorized and hydraulic operated pumps with either a continuous or pulsed operation for series progressive, parallel injector, parallel dual line, single line resistance, pump-to-point, spray systems, etc. 387780 Specifications Enclosure: • Plastic with Clear Cover, NEMA 4x, IP66 Display: • LCD – 2 Lines, 16 Characters per line • Up to 4 digits per entry • 3 LEDs – Power (Green), Fault (Red), Lube (Yellow) Machine cycles counts shown in main display Input power, current consumption (less load): • 85-135 V ac / 0.2 amp. • 120-265 V ac / 0.1 amp • 10-30 V dc / 0.4 amp External pump load: • 12 Vdc – 230 Vac, 50-60 Hz • 10 amp relay output (external fused by user, matched to equipment used) Fault output load: • 12 Vdc – 230 Vac, 50-60 Hz • 10 amp relay output (external fused by user,matched to equipment used) Ambient temperature range storage: • -10 to 160° F (-23 to 71○ C) Ambient temperature range operational: • 0 to 120° F (-18 to 48○ C) Vibration • Capable of withstanding 0.04 g2/Hz from 20 to 2000 Hz Wire size • Removable terminal blocks for maximum 14 AWG wire. Terminal blocks may be removed by placing a flat screw driver in the slot at the back of the block and twisting. The blocks swing up and out. Reverse to attach. Switch Inputs • There are three switch inputs: Lube Cycle, Machine Cycle Count and Manual Run. The circuitry supports dry contact or proximity switch options for the Lube Cycle and Machine Cycle Count inputs. Input (lube) Count rate • 10 Hz max. (600 CPM) Lube Cycle/Machine Cycle/Manual Run switch inputs • Dry contact, 24 Vdc, 2.5 mA max. Note: 24 Vdc is supplied by the CLS 1000 Programming: • Lube off time - 1 to 9999 secs, mins, hrs, or counts • Lube on time - 1 to 9999 secs, mins, hrs, or counts • Timing accuracy – 0.1% • Machine cycle counts – 0.5 – 99.5 by half counts • Pump – Continuous or Pulsed o Pulse off time – 3 seconds fixed o Pulse on time – 0 to 99 seconds • Pre-lube power up mode can be programmed Program Entry • 6 Push Buttons – Menu, Enter and 4 Arrow keys Alemite Corporation 167 Roweland Drive, Johnson City, Tennessee 37601 www.alemite.com 670864 Copyright© 2006 bu Alemite, LLC This document contains confidential information that is the property of Alemite, LLC and is not to be copied, used, or disclosed to others without express written permission. SER 387780 Revision (11-06) SER 387780 Centralized Lubrication System Controller CLS 1000 Service Guide Contents General Description …............................................................................................................3 Operation ………….…………………………………………………………………………4 Modes of Operation- Set Up Mode (Overview)………………………………………….......5 Modes of Operation – Set Up Mode (Programming)..……………………………………….5 Manual Run Mode ……………………………………………………………………….10 Wiring Connections ………………………………………………………………………11 Supply Power Wiring Examples .…………………………………………………..13 Pump Power/Control and External Alarm Wiring Examples …..………………….15 Input Switch/Sensor Wiring Examples …………………………………………….18 General Wiring Examples ………………………………………………………..23 Revision (11-06) 2 Alemite Corporation Idle Time This is the time between scheduled lubrication cycles as set up in seconds. Please refer to Figure 1 as needed when reviewing the definitions. Down Arrow (▼) Decrements a selected digit up by one or selects an operation per indicated instructions.Centralized Lubrication System Controller SER 387780 General Description Lubricant Dispensing The dispensing of lubricant can be scheduled and monitored using three key values. The user can select to continue lubrication cycles or to stop them until the fault is corrected and/or cleared. POWER (Green) • This LED indicates that power is applied to the Lube Controller. Right Arrow ( ►) Moves a display selection to the right. micro. or proximity switch) sends an electronic signal back to the Lube Controller. Alemite Corporation 3 Revision (11-06) . the CLS 1000. ENTER Pressing the ENTER key will cause the Lube Controller to save the displayed data and transition to the next step. operating instructions. LUBE (Yellow) • This LED indicates that the pump is on and lubricant is being applied. Operator Key Pad The six operator keys provide the following for operator inputs. Liquid Crystal Display The LCD provides operating status. Figure 1: CLS 1000 Lube Controller Displays and Keys A sketch of the front view of the CLS 1000 Lube Controller can be seen in Figure 1. FAULT (Red) • Indicates that a fault condition has been detected. hours or machine counts. Cycle Count This is the number of divider valve cycles to dispense the proper amount of lubricant. Alarm Interval This is the maximum time or machine counts allowed for a lubrication cycle to be completed. Along with the keys the display provides for easy set up and operation of the Lube Controller. a fault condition is generated. The following description provides an overview of the components of MENU This key allows the user to set up the controller's operation. If this time or count is reached before the entered Cycle Count is reached. Up Arrow (▲) Increments a selected digit up by one or selects an operation per indicated instructions. Display and Key Definitions Light Emitting Diodes The three LED's provide a quick view of controller status. minutes. It will command the Lube Controller to move between the Set Up and Auto Run modes. Left Arrow (◄ ) Moves a display selection to the left. setup information and fault information on 2 lines with up to 16-characters on each line. An end-of-cycle switch (limit. where the cycles or half cycles are counted. X counts” or “Lube” “Alarm off” “XXXX [alarm units]” Power Up in Idle Time The Lube Controller starts the count for the idle period of the lubrication cycle if that selection has been made during set up. Power Up (with lubrication cycle) The Lube Controller performs a lubrication cycle upon power up if that selection has been made during set up. See the section on Modes of Operation to see the setup sequence. The display shows: “Lube” “XX. Power Up (with no previous set up) If the Lube Controller is being operated for the first time the display shows: “Alemite CLS 1000” “No Setup” Pressing the MENU key will cause the Lube Controller to go to the Set Up mode. The display shows: “Idle” “XXXX [off or idle units]” Revision (11-06) 4 Alemite Corporation .SER 387780 Centralized Lubrication System Controller Operation Power Up Operation When power is applied the Lube Controller will go to one of 3 operating states. press the ENTER key. or hours) and the operating values. if the desired value is already displayed. SET UP MODE (Programming) Set Up Mode proceeds through the configuration steps in the following order. Use the Up and/or Down arrow keys to select the desired units. To move to another digit press the LEFT or RIGHT arrow key. The words on the display are shown in quotes “ ”. seconds. The configuration consists of units (counts. for each step. minutes. Once the desired values have been selected for all digits: Press the ENTER key. Set Up mode is also used to select pump output control (continuous or pulsed) and the desired function following an input power cycle or a fault condition. • The value displayed will be saved. Pressing the ENTER key performs two functions: • It saves the value displayed in the field • Moves the Set Up Mode to the next value or selection. The Set Up mode allows the user to configure the CLS 1000 Lube Controller for a dedicated application. Idle Units “Idle units” “Counts” or “Seconds” or “Minutes” or “Hours” This is the unit of measure of the delay between lubrications/cycles.Centralized Lubrication System Controller SER 387780 Modes of Operation Set Up Mode (Overview) Pressing the MENU key will cause the Lube Controller to go to the Set Up mode. • Moves the Set Up Mode to the next value or selection. Once another digit has been selected it will be underlined indicating that it will be modified if the UP or DOWN arrow key is pressed. Press the ENTER key to save the selected units and move to the Idle Time field. Alemite Corporation 5 Revision (11-06) . The digit to be modified will be underlined. During the Set Up process. Arrow Keys Each operating value requires an entry of up to 4 digits. To change the value of the underlined digit press the UP or DOWN arrow key to increment or decrement the underlined digits value. If the count is using full cycles or an even number of half-cycles then the number to the right of the decimal point will be a “0”. Revision (11-06) 6 Alemite Corporation . Press the ENTER key to save the Alarm Units value and move to the Alarm Time field. Hours) between lubrications. with no end-of-cycle) the lubrication cycle will be timed per the value selected for Alarm Units. If the count is using an odd number of half-cycles then the number to the right of the decimal point will be a “5”. If the application is using halfcycles then divide the number of half-cycles by 2 to determine the number of full cycles and enter that value. Use the Left and Right arrow keys to select between digits. Minutes.X cycles” When configuring the system to lubricate based on machine cycles this input will be the source of the machine cycle count.0” or one divider valve cycle. NOTE: Only 0 or 5 can be selected for the value to the right of the decimal point.0" counts are entered.5.0” is a special case as described below. fault detection is disabled. Use the Up and Down arrow keys to modify the digit to the desired value. Press the ENTER key to save the Cycle Counts value and move to the Alarm Units field. IMPORTANT: If a pressure switch is used in an injector system to signal a “Lube Cycle Complete” the cycle count should be 00. Note that the underlined digit is the one being changed.SER 387780 Idle Time “Idle time” “XXXX [idle units]” Centralized Lubrication System Controller This is the number of units (Counts. Use the Left and Right arrow keys to select between digits. Note that the underlined digit is the one being changed. IMPORTANT: If "00. The value “00. (using as a timer. The default value for Cycle Counts is “01. If "00. Enter the cycle count in the number of full cycles of the divider valve. Use the Up and Down arrow keys to modify the digit to the desired value. Alarm Units “Alarm Units” “Counts” or “Seconds” or “Minutes” or “Hours” Use the Up and/or Down arrow keys to select the desired units. Seconds. Press the ENTER key to save the Idle (or Off) Time value and move to the Cycle Counts field. Cycle Counts “Cycle Counts” “XX.0" counts are selected. Use the Left and Right arrow keys to select between digits. If the last pump “ON” cycle occurs before the selected divider valve cycle counts. Alemite Corporation 7 Revision (11-06) . “Continuous” is used for electric motors and reciprocating pumps. Note that the underlined digit is the one being changed. Press the ENTER key to save the Pulsed On Time value and move to the Pump Cycles field. Use the Left and Right arrow keys to select between digits. The “Pulsed” pump control means that the pump will be energized for a configured time period and then be de-energized for three seconds. allowing the piston to return to home position. If "Pulsed" is selected: Press the ENTER key to save the selection and move to Pulsed On Time. NOTE: The pump "off" time is always 3 seconds. the pump is held on until the number of divider valve cycle counts is reached or the alarm time is exceeded. If “Continuous” is selected: Press the ENTER key to save the selection and move to Power Up Mode. Use the Left and Right arrow keys to select between digits. Pump Cycles “Pump Cycles” “XX Cycles” Use the Up and Down arrow keys to modify the digit to the desired value. Pulsed On Time “Pulsed On Time” “XX Seconds” Use the Up and Down arrow keys to modify the digit to the desired value. Press the ENTER key to save the Alarm Time value and move to the Pump Control field. “Pulsed” is used for single stroke pumps requiring the air or hydraulic supply to stop. Press the ENTER key to save the Pump Cycles value and move to the Power Up Mode field. “Continuous” pump control means that the pump will be energized for the entire lubrication cycle either time or number of counts.Centralized Lubrication System Controller Alarm Time “Alarm Time” “XXXX [alarm units]” SER 387780 Use the Up and Down arrow keys to modify the digit to the desired value. Note that the underlined digit is the one being changed. Note that the underlined digit is the one being changed. Pump Control “Pump Control” “Continuous” or “Pulsed” Use the Up and/or Down arrow keys to select the desired pump control. If “Fault Lock Out” is set to “No” then the lubrication cycles will continue as configured but the fault condition and alarm will stay active. or in the Lube state with the pump activated to dispense lubricant. If “Idle” is selected then the CLS 1000 will wait for the configured time or cycle counts between lubrications before initiating the lubrication cycle. “Fault Lock Out” “Yes" or "No” Use the Up arrow and/or Down arrow to select the desired fault operation.. Pressing the MENU key will place the CLS 1000 into the Auto Run Mode. The Yellow (Lube) LED and Red (Fault) LED will be off.SER 387780 Power Up Mode Centralized Lubrication System Controller The Power Up Mode determines the operation of the CLS 1000 upon each power up event. If the “Fault Lock Out” is set to “Yes” then no more lubrication cycles will occur until the fault is cleared. timing down to the next lubrication cycle. If “Lube” is selected then upon power up the CLS 1000 will immediately initiate a lubrication cycle. Idle “Idle” “XXXX [off or idle units]” The units show the time or machine counts before the next lubrication cycle. Please note that the configuration mode may be activated at anytime by pressing the MENU key. Auto Run Mode During normal (no fault) operation in the Auto Run mode. the Lube Controller will be either in an Idle state. “Power Up Mode” “Lube" or "Idle” Use the Up arrow and/or Down arrow to select the desired power up operation. Revision (11-06) 8 Alemite Corporation . Press the ENTER key to save Power Up Mode value and move to the Fault Lock Out field. The controller will remain in the Set Up mode and cycle back through the configuration sequence. Press the ENTER key to save the Fault Lock Out setting. With this field the configuration process has been completed. Fault Lock Out This field determines the operation of the CLS 1000 in case of a lubrication fault. “Fault” “Enter to reset” After investigation and correction of the fault conditions: Press the ENTER key to clear the fault and the lubrication cycles will resume. If a Fault Lock Out has not been selected during configuration. The Yellow LED will be on and the Red LED will be off. the controller continues to run lubrication cycles per the selected Set Up values operation. a fault will stop the programmed lubrication cycles. Lube (with 00. The Yellow (Lube) LED will be on and the Red (Fault) LED will be off.0 cycle counts) “Lube” “Alarm off” “XXXX [alarm units]” The units show the time remaining in the current lubrication cycle.5 or more cycle counts) “Lube” “XX. the Red (Fault) LED will come on and the Alarm Contact will be closed. The LCD will show the fault and the Alarm Contact will be closed.Centralized Lubrication System Controller Lube (with 00. Fault If a fault (alarm time or machine counts are reached before the cycle is complete) is detected.X counts” (or “strokes”) SER 387780 The units show the counts remaining in the current lubrication cycle. If a Fault Lock Out has been selected during configuration. The lubrication operation in progress is halted. Alemite Corporation 9 Revision (11-06) . NOTE: The Red LED remains On and the Alarm Contact remains closed until the ENTER key is pressed to clear the fault. Revision (11-06) 10 Alemite Corporation . Auto Run will resume after one lubrication period. Please refer to Figures 3 and 11 for connector location and wiring examples. If this Manual Run switch is pressed during Auto Run mode or during a Fault Lock Out it will cause the controller to run a single lubrication period per the values that have been set up.SER 387780 Centralized Lubrication System Controller Manual Run Mode There is a Manual Run switch located on the upper side of the CLS 1000. If there is a no fault condition or a fault with no Fault Lock Out. the Fault Lock Out will continue after one lubrication period. If there is a fault condition and a Fault Lock Out has occurred. Manual Run Switch Figure 2: CLS 1000 Lube Controller show location of the Manual Run Switch There is also a provision to wire a remote Manual Run which will perform the same function as the local Manual Run switch. The following sections discuss the typical wiring connections for each of the three terminal block sections. Alemite Corporation 11 Revision (11-06) . consisting of terminals 1 thru 7 is for power wiring connections.Centralized Lubrication System Controller SER 387780 Wiring Connections The next section will describe some of the typical wiring connections used when installing the CLS 1000. Lube Cycle and Manual Run inputs. is for the external pump and fault relay connections. is for the contact and proximity sensor connections. The Supply Power Wiring section will provide typical power wiring examples for 115 VAC (nominal). The section on input sensor wiring will proved typical wiring connections for Machine Cycle. Each of the three terminal block sections has a specific purpose. 230 VAC (nominal) and 30 VDC (nominal). consisting of terminals 15 thru 21. This information may also be seen on the CLS 1000 circuit board just below the connector. The first. The final wiring section will provide wiring diagrams that show several typical complete wiring installation diagrams. The third terminal block section. The blocks swing up and out. The wiring connector has a total of 21 terminals divided into three sections of 7 terminals. The second terminal block section. Figure 3 shows the CLS 1000 connector terminal number and description. The Pump Power and External Alarm Wiring section will provide typical examples using the same power source as supplies the CLS 1000 as well as using a separate power source. The terminal block may be removed by placing a flat screw driver in the slot at the back of the block and twisting. consisting of terminals 8 thru 14. SER 387780 Centralized Lubrication System Controller Figure 3: Silkscreen of the CLS 1000 Connector Descriptions Revision (11-06) 12 Alemite Corporation . Centralized Lubrication System Controller SER 387780 Supply Power Wiring Examples The following diagrams gives wiring examples for the first terminal block section. These connections provide power to the CLS 1000 electronics. Figure 4: 85 – 135 VAC. consisting of terminals 1 thru 7. 0.2 amp Power Connection Figure 5: 170 – 265 VAC. which supply operating power to the CLS 1000. 0.1 amp Power Connection Alemite Corporation 13 Revision (11-06) . 0.4 amp Power Connection Revision (11-06) 14 Alemite Corporation .SER 387780 Centralized Lubrication System Controller Figure 6: 10-30 VDC. pump and external alarm power is supplied by the same source as powers the CLS 1000.9 for the pump and terminal connections 11. It should be noted that the pump and external alarm are not required to be powered from the same source as the one which supplies the CLS 1000. The fuse must be large enough to allow normal operation of all of the devices but small enough to provide protection. such as the pump and alarming device.12. The CLS 1000 does not supply power to external devices. If the pump to be used required more that the power (amperage) available then an interposing relay may be used to control a pump fed from a separate power source.Centralized Lubrication System Controller SER 387780 Pump Power/Control and External Alarm Wiring Examples The following wiring diagrams show examples of wiring control circuits for pumps and external alarm devices which are connected via the second terminal block section containing terminals 8 thru 14. When selecting a fuse size the equipment sizes need to be taken into consideration. If the devices are being supplied from a power supply other that that supplying the CLS 1000 then those devices should be fused separately. the connection to terminal pair 8. In this case. Figure 7: 85 – 135 VAC Power Connection with Pump Power and External Alarm Connections Alemite Corporation 15 Revision (11-06) .13 for the external alarm will be connected to the device power supply (See Figure 10). but controls the power fed to them via an internal 10 amp relay representations of which may be seen in the wiring diagrams. In typical applications. This example is seen in the following diagrams. SER 387780 Centralized Lubrication System Controller Figure 8: 170 -265 VAC Power Connection with Pump Power and External Alarm Connections Figure 9: 10 – 30 VDC Power Connection with Pump Power and External Alarm Connections Revision (11-06) 16 Alemite Corporation . Centralized Lubrication System Controller SER 387780 Figure 10: 85 – 135 VAC Controller Power with DC Pump and Alarm Power Alemite Corporation 17 Revision (11-06) . The CLS 1000 utilizes external contacts and sensors to provide the necessary control signals. Figure 11: Remote Manual Run Switch Connection using a Momentary NO Dry Contact Revision (11-06) 18 Alemite Corporation . Manual Run Switch The Manual Run input allows the user to wire a remote switch which will perform the same function as the Manual Run Switch located on the top of the CLS 1000 (see page 10). To make the required connections easier the CLS 1000 provides a DC voltage source adequate to power the dry contact and proximity sensor circuits. It should be noted that this DC voltage source is designed to power the sensor circuits and should not be utilized to supply power to any other circuits. This terminal block provides the connections for the contacts and proximity sensors that provide the control signals to the CLS 1000.SER 387780 Centralized Lubrication System Controller Input Switch/Sensor Wiring Examples This third section of wiring examples deals with the third terminal block section which consists of terminals 15 thru 21. In the circuit in Figure 12.Centralized Lubrication System Controller Machine Cycle Input SER 387780 In typical applications there is some delay between lubrication cycles. to open and then back to close. to the secondary position and then back again. A machine cycle is defined as the changing of the position of the contact from its original position. If the delay is determined by a number of events occurring then the Machine Cycle Input is used. a machine cycle would be the changing of the dry contact from close. Figure 12: Machine Cycle Indicator Connection using a Dry Contact Input Alemite Corporation 19 Revision (11-06) . This input can utilize dry contacts or a proximity sensor. hours) or by an event such as some number of machine cycles. The following diagrams show typical connections schemes for various sensor types. minutes. In this instance an NO or a NC dry contact could be used. This delay may be measured in time (seconds. These proximity switches are semiconductor devices that require power to function and change state based on whether metal is present or not.SER 387780 Centralized Lubrication System Controller The CLS 1000 is able to use proximity sensors in addition to dry contacts as input devices. Figure 13: Machine Cycle Indicator Connection using NPN Proximity Switch Figure 14: Machine Cycle Indicator Connection using PNP Proximity Switch Revision (11-06) 20 Alemite Corporation . power is connected to the DC+ and DC. As seen in Figure 13.wires of the proximity sensor. The signal output of the sensor is connected to the Machine Cycle Count input of the CLS 1000. Centralized Lubrication System Controller SER 387780 Figure 15: Lube Cycle Indicator Connection using Dry Contact Switch Figure 16: Lube Cycle Indicator Connection using NPN Proximity Switch Alemite Corporation 21 Revision (11-06) . SER 387780 Centralized Lubrication System Controller Figure 17: Lube Cycle Indicator Connection using PNP Proximity Switch Revision (11-06) 22 Alemite Corporation . Lube Cycle Dry Contact. Figure 18: 115 VAC Power. Low Level Dry Contact Switch NO Alemite Corporation 23 Revision (11-06) . Pump. Machine Cycle Dry Contact.Centralized Lubrication System Controller SER 387780 General Wiring Examples The following figures provide wiring examples for some of the more standard applications involving the CLS 1000. Pump. Lube Cycle Dry Contact Revision (11-06) 24 Alemite Corporation .SER 387780 Centralized Lubrication System Controller Figure 19: DC Power. Machine Cycle PNP Proximity Switch. Machine Cycle Dry Contact.Centralized Lubrication System Controller SER 387780 Figure 20: 230 VAC Power. Lube Cycle Dry Contact. Low Level Sensor PNP NC Alemite Corporation 25 Revision (11-06) . Low Level Sensor PNP NC Alternate Wiring. Same function as Figure 20 Revision (11-06) 26 Alemite Corporation . Machine Cycle Dry Contact. Lube Cycle Dry Contact.SER 387780 Centralized Lubrication System Controller Figure 21: 230 VAC Power. Lube Cycle Dry Contact. Machine Cycle Dry Contact. High Pressure Dry Contact NO.Centralized Lubrication System Controller SER 387780 Figure 22: 115 VAC Power. Low Level Dry Contact NO Alemite Corporation 27 Revision (11-06) . SER 387780 Centralized Lubrication System Controller Revision (11-06) 28 Alemite Corporation .