Lubecon Smart lube 2000 User manual

LubeCon

Smart Lube 2000

Multi Function Lubrication System

Controller

The purpose of this document is to provide a basic

knowledge of the LubeCon System for the Extrusion

Maintenance Department so that it may be used to both

maintain the system and to facilitate its implementation

into the remaining run-out tables.

Starting with the main display, each controller consists of

four separate channels. The statuses of these channels are

represented by the four clock symbols in the upper right.

At the time of this snapshot channel one was actively being

displayed showing it in a "Wait" state as indicated by the

clock symbol with the "Underline" beneath it. It is also

showing a cycle count of 215 and a "Tick" count of 94 with

both indicating how much "Run Time" remains until the next

"Lube-Cycle". Which, when active, will be indicated by an

Oil Can symbol in place of the clock symbol.

The artwork of the main circuit board within the controller

is divided into 4 regions/channels from left to right with

the outputs/Lube-solenoid drivers at the top and the

inputs/Magnetic-pickup connections at the bottom. Several

rows of terminal lugs exist numbered from left to right in

two groups of eight. For the left region of eight, lugs 1-4

represent channel 1 and 5-8 represent channel 2. For the

right region of eight, lugs 1-4 represent channel 3 and 5-8

represent channel 4.

Bus 1

Bus 2

The white wire which jumpers across bus 2:chan 1:pin 1 to

chan 2:pin5 to chan 3:pin 1 to chan 4:pin 5 is a "Lube

Request" signal from all 4 regions back to the pump station

to start the pump whenever any of the regions reach the end

of their "Wait Cycle" and need pressure to fire their

solenoids to apply lubricant to their supported area. Bus2

chanl:1-pin:4 is the output for the solenoid for that

region and a common for that solenoid can be picked up

along bus:1. Channel:2 would be pin:8. On the right,

Chan:3-pin:4 and Chan:4-Pin8. A small LED indicator on the

top of the controller shares these connection points for

each channel as an indicator for when the lube solenoid is

firing.

1 grnd 4 5 grnd 8

Chnl 1 Chnl 2

Chnl 3 Chnl 4

Bus 3, 4, and 5 maintain the same left to right regions as

above but provide inputs from the magnetic pickups

supporting each region/channel. With Bus:3 –pin:4 being

the signal input, Bus:4 –pin:4 being the +24v supplied to

the pickup, and Bus:5 –pin:4 being the ground for chan:1.

+24VDC is supplied from the pumping station to the

controller via the connections beneath bus 5.

Routine Checks:

Daily checks should be made.

The inspecting individual should verify that each

"Configured" channel is counting down by viewing the "Tick"

count on the front controller display while the appropriate

channel is being displayed and its monitored input is in

motion. The Lube output jets should be inspected to insure

that they have made it through the night without being

damaged and are still aligned to point in parallel with the

chain to allow the pulsed output of lubricant to lay on top

of the chain hitting multiple links with each squirt.

The pump station should also be observed to insure

that it is not in alarm, the lube line is holding pressure

and the tank level indicator flag is not nearing empty.

Pump station Control Panel

The low pressure alarm contact points were a programmable

option... ($$$) So, a McMaster Carr P/N=3427K1 pressure

switch was ordered, set, and placed in parallel with the

tank Lube Level Switch. The whole point being to force an

alarm and avoid pumping lube out onto the floor should the

lube line get damaged, and it has, and it works.

Zone 1Zone 1

Controller Setup / Programming

Initially, intentions were to use Channel 1 for Run-out

table #2s' Flight-Bar chain and Channel 2 for its primary

chain drive. This would leave channel 3 and 4 to be used

for identical purposes on press 1.

The individual channel profiles can be viewed/changed by

entering program mode on the Controller by pressing <Prog>.

The following settings create a "Run time" counter which

initiates one lube cycle for approximately every twelve and

a half hours of actual run time. The lube cycle equals

approximately 2 minutes 5 seconds. (The approximate time it

takes for the run-out table to cycle / revolve one time.)

<Prog>

Controller replies with: "Password needed to edit"

(Use the number pad and left or right arrows to chose)

<1234>

<Enter>

Controller replies with: "Select Channel"

(Use left or right arrows to chose)

<1>

<Enter>

Controller replies with: "select channel 1 run mode"

(Use left or right arrows to chose)

<Enter>

Controller replies with: "Channel 1 on counts"

(Use the number pad and left or right arrows to chose)

<250> Indicates the number of "0.5 second pulses" which

equal 1 cycle. (This value multiplied by the "Inter-count

delay" will determine how long to apply lubricant once the

Wait time / "Off Cycles" expire. (With current settings,

250 x 0.5 seconds equals 125 seconds.)

<Enter>

Controller replies with: "Channel 1 off cycles"

(Use the number pad and left or right arrows to chose)

<360> Indicates the number of cycles to "Wait/off cycles"

between Lube cycles.

360 x 125 = 45000 seconds

45000 / 60 = 750 minutes

750 / 60 = 12.5 hours of "run time/wait time" between lube

cycles.

<Enter>

Controller replies with: "Channel 1 on time"

(Use the number pad and left or right arrows to chose)

<.025> Indicates the length of time to hold Lube solenoid

open between "lube on counts"

<Enter>

Controller replies with: "Channel 1 lube delay"

(Use the number pad and left or right arrows to chose)

<.025> Indicates the desired delay between lube

applications. (This will be overridden by the fact that the

"inter count delay" below is longer.)

<Enter>

Controller replies with: "inter count Delay"

(Use the number pad and left or right arrows to chose)

<0.5> This indicates the time delay between counting a

pulse received by the magnetic pickup. This provides the

base for our "Run Time" environment. (We look for a

pulse/"Tick" every half second regardless of the sprocket

speed.)

<Enter>

Controller replies with: "low lube shutoff"

(Use left or right arrows to chose)

<Enable> This is another input adjacent to the magnetic

pickup inputs for use in other configurations. Enable it

anyway...

<Enter>

Controller replies with: "High pressure shutoff"

(Use left or right arrows to chose)

<Enable> This is another input adjacent to the magnetic

pickup inputs for use in other configurations. Enable it

anyway...

<Enter>

Controller replies with: "restart channel?"

(Use left or right arrows to chose)

<Yes> This will restart the channel and initiate a lube

cycle.

This can be done to manually initiate a Lube Cycle by

simply entering Program mode and stepping/Entering through

all settings (WITHOUT CHANGING ANYTHING!!!) to this point

and choosing "yes".

<No> will end/save/close channel 1 configure settings

without resetting the counters and starting a lube cycle.

<Enter>

Controller replies with: "enter channel to edit"

(Use left or right arrows to chose)

<Exit> Or, chose next channel to edit...

<Enter> If Exit is chosen, screen returns to main display.

NOTES:_____________________________________________________

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LubeCon Smart Lube 2000 User manual

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