Muirhead 9252 User manual

PRODUCT MANUAL
PROGRAMMABLE LUBRICATION
CONTROLLER
Part No. 9252

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DISCLAIMER
© Remote Control Technologies Pty Ltd.
■ No part of this manual may be reproduced, copied, translated, or transmitted in any form or by any means without the written
permission of RCT.
■ Information provided in this manual is intended to be accurate and reliable. However, RCT assumes no responsibility for its use or
infringements upon the rights of third parties that may result from its use.
■ All examples and diagrams shown in this manual are intended only as an aid to understanding the text, not to guarantee operation.
RCT will accept no responsibility for actual use of the product based on these illustrative examples.
■ Please contact your nearest RCT branch for more information concerning applications in life critical situations or high reliability.
■ RCT reserves the right to make changes to any product herein to improve reliability, function or design. All specifications are subject
to change without notice.

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Contents
General Safety Warnings 6
Personal Safety 6
Machine 6
Product 6
Product Overview 7
Features and Functions 7
Operation and Use 8
Control Unit 8
Inputs 8
Outputs 9
LED Indication 9
Software Options 9
Installation Guide 10
Wiring Connections 10
Wiring Connections for part number 4606 and 3560 10
Wiring Diagrams 11
−Single Bank System – External Wiring Diagram (427i) 11
−Dual Bank System – External Wiring Diagram (427h) 12
−Basic Programming Adaptor Lead – External Wiring Diagram (427j) 13
−In-Line Programming Adaptor Lead – Loom Configuration (423a) 14
Calibration 15
Software Detailed Description and Advanced Configuration 15
Home Screen 15
−Simulating a Lube Controller 15
−Connecting via COM Port 16
−Upgrading the Device 16
Main Setup Screen 16
−Layout 16
Section 1 – Tabbed Browsing of Devices 17
Section 2 – Toolbar Buttons 17
Section 3 – Inputs Section 18
Section 4 – System State 20
Section 5 – Outputs/Indicators 22
Testing and Simulation 23
−Testing a Physical Lube Controller 23
−Running a Simulation 23
Factory Default Settings 24
−Lubrication Options 24
−Timer Settings 24
−Alarm Options 24
−Advanced Settings 24
Service Information 24
Service Schedule 24
Service Procedure 24
Parts List 25
Technical Specifications 25

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Compliance and Standards 25
Troubleshooting 25
Glossary 26
Warranty 26
Revision History 27

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Table of Figures
Figure 1 Programmable lubrication controller .................................................................................................. 7
Figure 2 Drawing 427i Single bank system external wiring diagram.............................................................. 11
Figure 3 Drawing 427h Dual bank system external wiring diagram............................................................... 12
Figure 4 Drawing 427j Basic programming adaptor lead external wiring diagram......................................... 13
Figure 5 Drawing 423a – In-line programming adaptor lead loom configuration ........................................... 14
Figure 6 Lube controller application ............................................................................................................... 15
Figure 7 Home screen – lube controller application....................................................................................... 15
Figure 8 Layout of the main set-up screen..................................................................................................... 16
Figure 9 Device (a) tab & serial number, and (b) firmware version................................................................ 17
Figure 10 Toolbar for (a) general connected device, and (b) simulated lube controller................................. 17
Figure 11 Inputs layout................................................................................................................................... 18
Figure 12 Options section for a lube controller............................................................................................... 19
Figure 13 Device Info example....................................................................................................................... 20
Figure 14 Lube controller counters................................................................................................................. 20
Figure 15 Timers running for a lube controller................................................................................................ 20
Figure 16 Outputs layout ................................................................................................................................ 22
Figure 17 LEDs section .................................................................................................................................. 22
Figure 18 Override example........................................................................................................................... 23

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General Safety Warnings
Personal Safety
■Everyone is responsible for safety.
■The installer/service personnel should be trained and authorized to complete the required work.
■Ensure that the machine is safely isolated during installation and testing to protect all personnel.
■Complete all required risk assessments and job safety analysis (JSA) before commencing work.
■Observe all site specific and machine OEM procedures regarding the following:
– working at heights
– working in heat
– working in confined spaces
– all other site specific occupational health and safety (OH&S) procedures
Machine
■Carry out all pre-start operations as per site and machine OEM procedures.
■Ensure the machine is safely isolated during installation and testing to protect the machine and other
equipment in the area.
■Do not operate any machine with a known fault and report all findings to the supervisor in writing.
■Test and operate machine as per machine OEM and site procedures.
■Read and understand machine and site specific operational and testing instructions.
Product
Before applying power to the equipment, the user/repairer/installer must read all product instructions. If in
doubt, seek assistance.
■Ensure electrical connections are made as per RCT’s recommendations. Test circuits prior to connecting
power to any component.
■The equipment contains no user serviceable parts inside. Return the unit to RCT for repairs.
■Retain product and installation instructions for future use.
■Ensure that RCT’s recommended service procedures are included in the machine’s service routine.
■Observe all machine, site and RCT product warnings.
■Follow all machine, site and RCT product operating procedures at all time.
The application of safety should not be limited to the above recommendations.

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Product Overview
Figure 1Programmable lubrication controller
The Muirhead®Programmable Lubrication Controller, part number 9252, is designed for flexibility and is used
to automate the grease injection system on a machine.
The programmable lubrication (lube) controller is capable of operating in many different modes to suit multiple
lubrication systems available on the market. In the standard pump solenoid valve pressure switch
arrangement, the system can be programmed so that the pump can act as a reciprocating pump where it
requires a pulse circuit or it can just switch a pump on. The system provides the option to use a pressure
switch. The pause and pump periods can be adjusted from 0.5 seconds to up to 24 hours. It can also be easily
configured to act as a swap version where it activates a lube cycle on one bank for a period, then swaps over
and operates a second bank with full pressure switch monitoring.
The system has many diagnostic capabilities and when connected to the custom software package, the
complete system can be monitored.
Features and Functions
■Pressure switch monitoring
■Pulse or continuous pump
■Adjustable pause and pump periods from 0.5 seconds to 24 hours
■Swap between banks
■Manual pump mode
■Grease low level indication
■Customised software
■Inbuilt diagnostics
■12 or 24 volt machines
■Suits various lubrication systems
■Fully software configurable to suit all machine types
■One panel to suit all machines on site
■Modular design
■Internal alarm

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Operation and Use
The Muirhead®Programmable Lubrication Controller has been designed with flexibility in mind. The system is
capable of operating in many different modes which suit multiple lubrication systems.
Control Unit
The lube controller has been designed to be an in-cabin mounted device.
Note
The lube controller is not IP rated for external mount.
The lube controller incorporates a manual lube cycle button that activates a cycle if pushed, as well as an
internal audible alarm.
The lube controller has LED indication and inbuilt diagnostics to aid fault finding. It also incorporates options
for low level detection, an external manual lube button and also an external alarm circuit. All calibrations and
programming are performed using a user-friendly software program via a notebook computer.
The programs can be saved and later loaded into multiple units if required and can be calibrated to suit all
types and variations of machines.
The power supply requirements are 8 to 36 volts dc and therefore suits all 12 and 24 volts dc machines.
The information below describes the operation of every function of the programmable lube controller, including
the inputs, outputs, LED indicators, and software options.
Inputs
Pressure switch 1 input This input can be configured to sense a positive or a negative and can be
normally open or normally closed. The options are software adjustable. The
standard configuration is negative and normally open, only closing when
pressure is achieved.
Pressure switch 2 input This input can be configured to sense a positive or a negative and can be
normally open or normally closed. The options are software adjustable. The
standard configuration is negative and normally open, only closing when
pressure is achieved. This input is only used on systems that require two
pressure switch inputs.
Low grease level input This input can be configured to sense a positive or a negative and can be
normally open or normally closed. The options are software adjustable. The
standard configuration is negative and normally open, only closing when a low
level is detected. This input is optional, if level monitoring is not available, do
not use this input.
External lube cycle input This input can only sense a positive signal. However, it can be configured to
be normally open or normally closed. The options are software adjustable.
The standard configuration is normally open, closing when a lube cycle is
required. This input is optional and acts exactly the same as the cycle button
on the lube controller.
Cycle push button Pressing this button activates a lube cycle. It bypasses the pause period. It is
generally used by the operator if they think extra lube is required. An additional
feature of this push button is when the unit is in alarm mode pressing this
button will mute the alarm for 10 minutes.

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Outputs
Pump output This connection is a positive switching FET output. Rated up to 8 A, this output
is used to operate the lube pump. The active time period for this output is
software configurable.
Pulse output This connection is a positive switching FET output. Rated up to 8 A, this output
is used to control a pulsing circuit to drive a reciprocating pump. Both the pulse
on and off periods for this output are software configurable. This output can
also act as a swap output for dual bank systems. The selection of the swap
circuit is software configurable.
Alarm output This connection is a positive switching FET output. Rated up to 2 A, this output
is used to activate a remote mount alarm or visual indicator. This circuit is
optional due to the fact that the lube controller has an internal audible alarm.
The alarm output is software configurable to be on continuous pulse failure
warnings and not to operate at all.
LED Indication
Power on This indicator illuminates green when the unit is switched on.
Pump This indicator illuminates green when the pump output is active.
Pulse This indicator illuminates green when the pulse output is active. For a lube
controller configured for a two lube bank system, the indicator indicates that
the swap solenoid is active.
Press 1 This indicator illuminates amber when pressure switch 1 is active. It displays
one pulse if the lube cycle failed to reach pressure within its lube period,
indicating a possible broken line. It displays two pulses if the lube pressure is
achieved too quickly, indicating a possible blocked line.
Press 2 This indicator illuminates amber when pressure switch 2 is active. It displays
one pulse if the lube cycle failed to reach pressure within its lube period,
indicating a possible broken line. It displays two pulses if the lube pressure is
achieved too quickly, Indicating a possible blocked line.
Level This indicator illuminates red and pulses whenever the low grease level is
detected.
Software Options
Lockout pump When enabled, the lubrication pump is locked out after an open failure.
Lube at power up When enabled, the lube cycle is activated as soon as power is applied.
Two lubes banks (swap) When enabled, the lube controller operates two lubrication banks by operating
as a swap circuit.
Pulse low grease alarm The low grease alarm can be set to either pulsed or continuous during a low
grease fault.
Pulse low grease output The low grease output can be set to either pulsing or continuous during a low
grease fault.
No pressure switch The lube controller can be set up to operate with no pressure switch inputs.
Therefore no fault conditions occur when set up this way.
No sonar alert The internal sonar alert can be disabled.
External manual lube When selected it allows the unit to accept an input from an external manual
lube switch.

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Installation Guide
1. Install the lube controller in a suitable location away from moisture and dust, preferably in the cabin area
where the operator has access.
2. Refer to the wiring table below and the specific wiring diagrams (that suits the system being installed) in
this manual to connect the lube controller. It is recommended that the wiring is installed alongside the OEM
wiring ensuring that it is secured at regular intervals; this will provide protection from heat and abrasion,
and any other excess damage that may occur with extended vehicle operation. When securing the wiring
to the OEM wiring, ensure that the loom is away from moving vehicle parts which could lead to loom
damage.
The following table details the different pin and wiring connections available on the lube controller.
Wiring Connections
No. Signal Description
1 Ignition 8 to 36 Vdc
2 Ground 0 Vdc
3 Output (pump solenoid) 8 A inductive (supply volts)
4 Output (pulse solenoid) 8 A inductive (supply volts)
5 Output (external alarm) 2 A resistive (supply volts)
6 Digital input (pressure switch 1) Active −or + (default is −)
7 Digital input (pressure switch 2) Active −or + (default is −)
8 Digital input (low lube level) Active −or + (default is −)
9 Digital input (external manual cycle) Active +
10 Data ground 0 Vdc
11 RS 232 RX (receive) Data
12 RS 232 TX (transmit) Data
Wiring Connections for part number 4606 and 3560
When removing one of these part numbers and replacing with a 9252 please use connection details below.
4606 and 3560 Wiring Connections 9252 Wiring Connections
No. Colour 8-pin Plug 12-pin Plug
1 Black Earth to Pin 2
2 Green Fault alarm +VE (optional) to Pin 5
3 White Pressure switch (N/O) to Pin 6 (Pin 7 optional second pressure switch)
4 Orange +12/24 V supply to Pin 1
5 Black/white Grease pump solenoid –VE to Not Used
6 Purple Grease pump solenoid +VE to Pin 3
7 Green/yellow Fault alarm –VE (optional) to Not Used
8 - Not used
There will be extra features when installing the 9252 please refer to the manual for connection details on these.