Graf SINGLE LUB 2 User manual

INSTRUCTION MANUAL
SINGLE LUB 2
Graf Chemicals GmbH Phone: [phone]
Prof.-Max-Lange-Platz 4 [e-mail]
83646 Bad Tölz –Germany www.graf-chemicals.com

Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 2
CONTENTS
1. GRAF Single Lub ………………………………………………………………………………
…..
. “ettig……………………………………………………………………………………………….
…..
. The cofiguratio eu…………………………………………………………………...
…..
. Error essages………………………………………………………………………………….
….
5. Technical data…………………………..……………………………………………………….
6. Complete oerie Error essages…………………………………………………..
….
….
7. Diagram electrical installation on winding machines…..…………………….
. EC Declaratio of Cofority…………………………………………………………….
….
….

1. Single Lub 2
Front side:
Status LED Input LED
display
Window for
visual operation
check
Magnet sensor
keys
A
B
C
Seal rubber
Sponge
type 1/2
Lubricant
injection
Open / Close
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 3

Rear view:
Connector cable to
winding machine
Connector cable
to applicator
Pump output
1/8 tube
connection
Lubricant input
1/8 tube
connection
Pump input
1/8 tube
connection
Connector cable
to dosing unit
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 4

Input display:
Keys work only
with magnetic pen
I/O
A
B
C
1 2 3
MODE
(touch the „a“ in the name graf)
Description of magnet sensor keys (input keys):
I/O
Key I/O turns on/off the lubricant metering.
On: the device is on stand-by
Off: the device is off, the heating is still on.
MODE
Key MODE switches unit to configuration mode.
Press the letter a i the ae graf.
Press key for 6 seconds (Key is only active when pump is not running,
green LED „A“ must be off).
1 2 3
Keys 1,2,3 to set numbers.
A short press on key increases number by one.
Description of magnet sensor keys (input keys):
A
Green LED lights up when product is being metered.
B
Yellow LED lights up when applicator is below operating temperature
(lower than 90% of pre-set temperature).
C
Red LED lights up when metering breaks down.
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 5

2. Setting
2.1 Programm version
After connecting device to mains electricity supply, display shows first a number indicating
version number of programme:
Here for example version 1.0
Immediately afterwards, unit shows last output setting in g/min.
Here for example unit is set to an output of 2.5 g/min.
2.2 Feeding Rate Calculation
To calculate the lubricant quantity setting for the dosing unit, please use the following
formula:
 
 
%lub
%
min
min activity
uptake
g
m
eff
Nm
m
dthreadspee
g
Setting 




















With:
Thread speed = winding speed
Uptake = quantity of lubricant to be applied to the yarn in % of yarn weight.
Nm = the weight of the yarn; how many meters of yarn per one (1) gram.
Lub activity = the % of active material (solid matter) in the lubricant






min
m
 
%






g
m
eff
 
%
Calculation example
Thread speed: 1200 m/min
Uptake: 3.5 %
Nm eff: 35 m/g
Lube activity: 100%
min
2.1
%10035
%5.3
min
1200
min
g
x
g
m
x
m
g
Setting 
device setting
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 6

NOTE: In speed clock operation mode CL 1 –CL 8 (see chapter 3) the input of the
lubricant feeding quantity is made in g/km (grams per kilometer of thread)
and not in g/min (grams per minute).
Calculation Example ONLY for setting CL 1 or CL 8
2.3 Setting of output
The output can now be adjusted using the keys 1, 2, 3. Each digit must be set separately.
With each press on the key, the corresponding number increases by 1.
Once the number 9 is passed, the unit return to zero.
 
 
%lub
1000%
activity
g
m
Nm
uptake
km
g
Setting
eff 














km
g
g
m
km
g
Setting 1
%10035
1000%5.3 









to set
To change for example to
press the key 1once, the key 2eight times and the key 3three times.
Thus the output of 2.5 g/min has been changed to 10.8 g/min. This setting
remains the same until the next adjustment, even if the device is disconnected in
the meantime.
2.4 Turn on/off
With the I/O key the pump can be turned off. The display indicates:
The luminous decimal point of the second digit indicates that the pump is in off mode and will
not meter even if the winding machine is working.
By another press on the I/O key the pump is changed to on mode and the display shows the
value which was indicated before. The applicator is still hot.
2.5 Applicator Temperature
The current applicator temperature can be displayed by pressing MODE key at short term. In this
mode, the display shows degree sign (°) plus the current applicator temperature in degrees Celsius.
In order to exit applicator temperature display mode, press the MODE key once more.
This mode just displays the current applicator temperature.
The applicator temperature can be changed within a range of 20 to 80 degrees Celsius by modifying
the AtP Applicator Temperature Value in the configuration menu (see chapter 3.)
The standard setting is 60 degrees Celsius.
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 7

operating
mode
.
12.3
□I/O
t.60
Test run
time based
t.01 .. t.99
The time based test run is for feeding
lubricant with the Quantity set at the
Operating Mode for a determined count of
seconds. The Run starts by pressing I/O and
stops automatically when the time count-
down has reached 00. The Test Run can be
aborted at any time by pressing I/O.
Default-value: t.60
b.05° 60
□MODE
3. The configuration menu:
The device can be configured for different applications by using the MODE key. By pressing
this key repeatedly, several points of the menu are passed through which can be configured
as required.
ATTENTION: Only enter the configuration menu if changes are absolutely necessary. A
careless change of any parameter may lead to a malfunction of the device.
To enter the configuration menu, the MODE key must be pressed for 3 sec. After the last
menu item has been passed, the configuration menu is left automatically.
To leave the configuration menu prematurely, the I/O key must be pressed. Changed
parameters are automatically saved.
The configuration menu is passed through in the following order:
Applicator-
temperature *
□I/O □MODE
Acceleration
ramp **
□MODE [3sec.]
Stand-by
□MODE [3sec.]
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 8
□MODE
□I/O
r.50
Test run
turn based
r.01 .. r.99
The turn based test run is for feeding
lubricant with the Quantity set at the
Operating Mode for a determined
number of gear wheel turns. The Test run
starts by pressing I/O and stops
automatically when the turns you have
set are done. The Test Run can be aborted
at any time by pressing I/O.
Default-value: r.50
□MODE

□I/O
CAL.
170
Calibration
of feeding
quantity
Pump
feeding
quantity
calibration.
□MODE
050 ..250
This value determines the calibration setting
of the pump head. The value set describes
the feeding quantity of the pump in
milligram / turn. At this menu point the
display shos alterately CAL ad the
value set.
Default-value: nothing
ATTENTION:
Setting this to an improper value leads to an
incorrect feeding quantity.
□I/O
F.65
Fluid
motion
controller
sensitivity
determines
sensitivity
of the flow
motion
controller.
F.00 ..F.99
The reaction time of the flow motion
controller can be set using this value. The
higher the value, the faster the fluid motion
controller reacts. Normal reaction delay
should be within 50 ..70 seconds.
Default-value: F.65
□MODE
The red LED Clights up when the reaction
point has been reached. For test purposes,
the moment the parameter F is entered, the
flow motion sensor starts to detect if
lubricant is flowing through the pump. As
the motor is not running and no lubricant is
moving in this mode, the flow motion
sensor should show an error after approx. 1
minute. The red LED Cindicates the error.
With the value 00 the flow motion sensor is
completely switched off.
ATTENTION:
If this value is changed (especially by
increasing the sensitivity), the red LED C
might light up during normal operation. The
control unit is already factory –set at the
value of 65, which corresponds to the
required sensitivity of approximately 1
minute after interruption of output. When
the red LED Clights up, the winding
machine is stopped by the metering device
(only if connected).
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 9

□I/O
A.02
Applicator
setting
determines
type of
applicator
used.
□MODE
A.00..A.03
A.00: Cold applicator, no check of
temperature
A.01: Cold applicator with Clean-Start
(1.5 rotations).
A.02: Hot applicator
A.03: Hot applicator with automatic
temperature reduction at standstill
* Temperature display only active with
activated hot applicator
□I/O
Ad.0
automatic
temperature
reduction
determines
delay of
temperature
decrease
□MODE
Ad.0..Ad.6
If A.03 (hot applicator with automatic
temperature reduction at standstill) was
selected in the applicator setting, this menu
item is activated and the time delay of the
automatic temperature reduction when the
pump is at a standstill can be specified in 6
steps.
Ad.0: No delay (immediate temperature
reduction at standstill)
Ad.1: temperature reduction 10 seconds after
standstill
Ad.2: temperature reduction 30 seconds after
standstill
Ad.3: temperature reduction 1 minute after
standstill
Ad.4: temperature reduction 2 minutes after
standstill
Ad.5: temperature reduction 5 minutes after
standstill
Ad.6: temperature reduction 10 minutes after
standstill
□I/O
AtP.
°60
Applicator
temperature
determines
temperature
of applicator
□MODE
°20 ..°80
At this menu point the control temperature of
the Hot Applicator (if connected and with
A.02 / A.03 activated) is set. The temperature
value between 20 and 80 degrees is entered
in ° C. At this menu point the display shows
alterately AtP. ad the alue set of
temperature.
Default-value: °60
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 10

□I/O
CL.0
Clock
operating
mode
determines
the clock
operating
mode.
□MODE
CL.0 ..CL.8
CL.0: No Clock Input
CL.1: With acceleration ramp
(ramp reset on every pump restart)
CL.2: With acceleration ramp
(ramp reset only on reset input
signal)
CL.3: Clock operating mode
CL.4: Clock operation mode with
clock-controlled release
CL.5: Clock-controlled release only
CL.6: Clock operation mode with
clock-drop-detection
CL.7: Clock operation mode with
clock-controlled release and
clock-drop-detection
CL.8: Clock-controlled release only with
clock-drop-detection
Default-value: CL.0
** Acceleration ramp only active with
corresponding setting
□I/O
C.10
Clock input
rate setting
determines
the clock
input rate in
pulses/ meter
□MODE
C.01 ..C.50
When the system is used on a winding
machine with a non-constant thread speed,
the system must be connected to a speed
signal equivalent to the thread speed. The
C.-Value must be equal to the count of
pulses per meter of thread, delivered by the
thread-reel on the
meter-counter. This menu item is only
activated if the setting CL.3 to CL.8 was
selected in the clock operating mode.
Default-value: C.10
The input signal is connected to the grey
cable (see Schematic diagram chapter 7).
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 11

□I/O
Yd.0
Yarn
Detector
Operating
Mode
Using this
mode, a Yarn
Detector can
be attached
to the
System
which
control star
and stop of
the pump
□MODE
Yd.0..Yd.2
In addition to the release of the pump
supply by means of an external release
signal and clock control, a pump release
can optionally be carried out with an
externally connected Yarn Detector.
Yd.0: No Yarn Detector used
Yd. 1: Yarn Detector with active-high
output signal used
Yd. 2 Yarn Detector with active-low output
signal used
Default-value: Yd. 0
□I/O
dP.0
Motor
decade and
gear setting
sets lub
quantity
decade
setting
□MODE
dP.0 /
d.P1 /
d.P2
dP.0: Feeding Quantity Input with 1 decade
after comma (e.g. 12.3 g/min)
dP.1: Feeding Quantity Input with 2
decades after comma
(e.g. 1.23 g/min)
dP.2: Feeding Quantity Input with 2
decades after comma –only for use
with 10:1 motor gear
(e.g. 1.23 g/min)
Default value: dP.0
□I/O
L.20
Maximum
Feeding
Quantity
Limitation
Limits the
max.
Adjustable
Lub Quantity
□MODE
L.05 ..L.40
This value limits the maximum settable
feeding quantity in operation mode to the
value set here, given in grams per minute
for non-clock-operation and grams per
1000 m of thread in clock operation
respectively.
Default-value: L.20
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 12

□I/O
u.05
Acceleration
time at
pump start
□MODE
u.00..u.30
This setting determines the acceleration
time from when the pump is started until
the feed quantity set has been reached.
With setting u.00, the pump feeds
immediately with the specified feeding
quantity.
Default-value: u.05
The value 05, for example, means that the
adjusted output is reached within 5
seconds after starting the pump. This value
should be chosen according to the
acceleration of the winding machine. The
minimum value is 0, the maximum value is
30 seconds.
□I/O
d.01
Deceleration
time at
pump stop
d.00..d.30
This setting determines the deceleration
time from when the pump is stopped until
the feed quantity is zero. With setting d.00
the pump stops immediately after
switching off.
Default-value: d.01
NOTE: deceleration begins at the moment
the pump is switched off.
END OF SETTINGS
Menu EXITS to set metering quantity
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 13

4.1 Nothing on the display
Possible cause
Remedial measures
Electronic fault
Check power supply
4. Error messages:
Should any fault happen during operation –for example, in the case of a cable break or if
the pump runs dry –this is indicated by an alarm signal and the winding machine is
automatically stopped (only if yellow cable is connected). If possible the display indicates the
corresponding error message.
The fault is indicated by a capital E in the first place followed by a number explaining the
cause of the fault.
4.2 Loss of data
The configuration steps of the device are lost.
Possible cause
Remedial measures
Processor IC on the printed
board has been exchanged
Create new settings in the
configuration menu
4.3 Failure of applicator (only with hot application)
The applicator has not reached the working temperature.
NOTE: This error message only appears during winding. Additionally to this error
message the yellow LED Blights up, also when the winding machine has already
been stopped.
The error message is automatically cancelled as soon as the applicator has
reached the nominal temperature.
Possible cause
Remedial measures
Applicator is still heating up
Wait for 5 minutes until the heating up
is finished
The internal connector of the
applicator is not plugged in at
the device
Check the connector
Applicator or device is out of
order
Exchange the applicator heater or the
device and send it for repair
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 14

4.4 No speed pulses (only for coupling with yarn speed)
Possible cause
Remedial measures
Device set to CL 3 or CL4 but
grey cable is not connected to
receive speed pulses
Connect grey cable or set to CL0, CL1
or CL2
Yarn has not been attached to
the wheel of the speed sensor
Attach yarn in such a way that the
wheel of the speed sensor turns with
yarn speed
The connector of the wheel is
not plugged in at the device
(grey cable)
Check connector
The wheel of the speed sensor
or the device is defective
Exchange the wheel or the device and
send in the part for repair
4.5 Breakdown of output, overtaxing
NOTE: This fault can only appear when output and yarn speed are coupled.
The clock signal of the winding machine is missing
The output capacity of the pump has been exceeded.
Possible cause
Remedial measures
The output has been set too
high
Regulate the output with a lower
value
The winding machine is running
too fast so that the pump
cannot meter the required
quantity of output
Reduce the winding speed
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 15

4.6 Alarm signal of the flow motion sensor
Possible cause
Remedial measures
The drum is empty: there is no
more product left
Check the lubricant in the drum
The plastic flexible tube
leading to the pump is buckled,
blocked or disconnected
Check all flexible tubes leading to and
coming from the pump and exchange
them if necessary
The applicator or the pump is
blocked
Clean applicator or pump
The output has been adjusted
to the value <00.3 g/min
Check the output setting
The sensitivity of the flow
motion sensor has been set
too high
Set the flow motion sensor to a lower
sesitiity see test ad setting of the
flo otio sesor
Device is defective
Exchange device and send it for repair.
The flow motion sensor indicates:
No product is being metered.
NOTE: The red LED C lights up in addition to this error message.
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 16

5. Technical data:
Operation
Connected to current:
10 –40 °C
Air humidity: 0 –80% (not condensating)
Storage
0 –50 °C
Air humidity: 0 –80% (not condensating)
Electrical data:
Power supply
24 VDC
Current consumption
Off mode 1W
Standby 2W
Running 5W
With hot applicator: heating 30W
With hot applicator: standby 15W
Dimensions (approx.)
100 mm
100 mm
140 mm
70 mm
60 mm
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 17

Error message
Error message description
Is displayed...
Action
Confirmation/Reset
E.00
System EEPROM Data Loss
The pumping device EEPROM has been deleted or
was not yet configured (new device)
Once the Error has occurred
Machine disabled
MODE or I/O Button
E.01
Pump Head EEPROM Data Loss
The pump head EEPROM has been deleted or was
not yet configured (new device)
Once the Error has occurred
Machine disabled
MODE or I/O Button
E.02
Pump Head EEPROM Erase Failure
The pump head EEPROM has not been deleted
successfully
Once the Error has occurred
Machine disabled
MODE or I/O Button
E.10
Hot Applicator Temperature Error
The Hot Applicator connected to the system is not
yet heated up entirely to its set temperature or
isn't able to keep its temperature level above a
fixed threshold of 5 degrees Celsius below the set
temperature by any reason. This error message is
only displayed when the error persists while the
pump is being started. The error message can
then be confirmed by the action described
As long as the Error is
persistent and the System
gets an external Run Signal.
Machine disabled
MODE or I/O Button
when there is no
external Run Signal or
when the Error
disappear by itself
E.11
Hot Applicator Sensor Error
The Hot Applicator connected to the system has a
faulty or broken NTC temperature sensor.
Alternatively, the power cord to the applicator
was damaged or the applicator isn't connected
properly
As long as the Error is
persistent and the System
gets an external Run Signal.
Machine disabled
MODE or I/O Button
when there is no
external Run Signal or
when the Error
disappear by itself
6. Complete overview Error messages
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 18

Error message
Error message description
Is displayed...
Action
Confirmation/Reset
E.20
Clock Input Signal Missing
This error message appears when the clock input
signal is missing or the Clock Signal Input
Frequency is below 0.5Hz while the Clock
Operating Mode is enabled at Clock Operating
Mode 2 or 3 and the pump is started.
As long as the Error is
persistent and the System
gets an external Run Signal.
No action
MODE or I/O Button
when there is no
external Run Signal or
when the Error
disappear by itself
E.21
Maximum Clock Signal Input Frequency Exceeded
The maximum allowable Clock Signal Input
Frequency in Clock Input Operation Mode 2 or 3
exceeds over ist computable range. In this case,
the Clock Signal Input Frequency is clamped at its
maximum limit. The range maximum limit is
1000Hz.
As long as the Error is
persistent and the System
gets an external Run Signal.
No action
No confirmation
possible
E.30
Maximum Feeding Quantity Exceeded
This error message appears when the motor
rotational speed is too high so that the motor may
not be able to keep track on this speed without
losing steps.
As long as the Error is
persistent and the System
gets an external Run Signal.
No action
No confirmation
possible
E.40
Fluid Motion Controller Flow Error
The Fluid Motion Controller has detected a
lubricant flow error.
Once the Error has occurred
Machine disabled
MODE or I/O Button
E.41
Pump Head Missing Error
The Pump has been started without a proper Pum
Head attached to the system
As long as the Error is
persistent and the System
gets an external Run Signal.
Machine disabled
MODE or I/O Button
when there is no
external Run Signal
E.42
Pump Head Fluid Motion Sensor Error
The Pump Head's Fluid Motion Sensor is faulty or
the wiring to the Sensor is broken
As long as the Error is
persistent and the System
gets an external Run Signal.
Machine disabled
MODE or I/O Button
when there is no
external Run Signal
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 19

Error message
Error message description
Is displayed...
Action
Confirmation/Reset
E.43
Pump Head Fluid Motion Sensor Offset Error
The Pump Head's Fluid Motion Sensor Offset DAC
is not calibrated or faulty or the wiring to the DAC
is broken
As long as the Error is
persistent and the System
gets an external Run Signal.
Machine disabled
MODE or I/O Button
when there is no
external Run Signal
E.44
Pump Head Fluid Motion Sensor ADC Error
The Pump Head's Fluid Motion Sensor Acquisition
ADC is not present or faulty
As long as the Error is
persistent and the System
gets an external Run Signal.
Machine disabled
MODE or I/O Button
when there is no
external Run Signal
E.50
Pump Test Run Error
The system has detected a problem during
execution of the Pump Test Run. The Pump Test
Run must be repeated
Once the Error has occurred
No action
MODE or I/O Button
E.51
Pump Test Feed Error
The system has detected a problem during
execution of the Pump Test Feed. The Pump Test
Feed must be repeated
Once the Error has occurred
No action
MODE or I/O Button
E.60
Machine Enable Output Error
The Machine Enable Output Transistor is
overloaded or shorted to +24VDC. Although the
output transistor is properly protected from this
condition, the Machine Enable Function may not
work. Consequently, system errors may not stop
the machine reliably.
As long as the Error is
persistent
Brings Transistor
Output in hiccup
mode as long as
condition persists
No confirmation
possible
E.61
Stepper Motor Driver Error
The Stepper Motor Driver reports an error or is in
fault condition
As long as the Error is
persistent and the System
gets an external Run Signal.
Machine disabled
MODE or I/O Button
when there is no
external Run Signal or
when the Error
disappear by itself
Instruction Manual GRAF SINGLE LUB 2 / Version 4.0 –05.2020 20