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
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)
<Counter>
<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)