SAFEMATIC ST-1100i User manual

SAFEGREASE, SAFEOIL
ST-1100i
110i1CEN.doc 16.04.2003 Rev. 1C
CONTROL CENTER ST-1100i
TABLE OF CONTENTS
1 GENERAL DESCRIPTION................................................................................................................................1
2 DESIGN.............................................................................................................................................................1
2.1 Cover...........................................................................................................................................................1
2.1.1 LED-signals..........................................................................................................................................1
2.1.2 Buttons .................................................................................................................................................1
2.2 Control Panel...............................................................................................................................................2
2.2.1 General.................................................................................................................................................2
2.2.2 Display..................................................................................................................................................2
2.2.3 Buttons .................................................................................................................................................2
2.2.4 LED-signals..........................................................................................................................................3
3 OPERATION......................................................................................................................................................4
3.1 Normal mode...............................................................................................................................................4
3.1.1 Phase codes for normal mode and alarm mode...................................................................................4
3.1.2 Normal mode displays..........................................................................................................................5
3.1.3 Line pressure displays..........................................................................................................................6
3.1.4 Returning to normal mode....................................................................................................................6
3.2 Extra lubrication...........................................................................................................................................7
3.3 Manual control.............................................................................................................................................7
3.4 Lubrication cycle counter ............................................................................................................................8
3.5 Power failure ...............................................................................................................................................8
3.6 Alarms.........................................................................................................................................................9
3.6.1 Low limit alarm......................................................................................................................................9
3.6.2 Pressure alarm.....................................................................................................................................9
3.6.3 Power failure alarm...............................................................................................................................9
3.6.4 Electronic system error alarm.............................................................................................................10
4 SETTINGS.......................................................................................................................................................10
4.1 General......................................................................................................................................................10
4.2 Entering settings........................................................................................................................................10
4.3 Entering password ....................................................................................................................................11
4.4 Setting mode.............................................................................................................................................11
4.4.1 Lubrication cycle counter....................................................................................................................11
4.4.2 Lubrication cycle.................................................................................................................................12
4.4.3 Maximum pressurization time.............................................................................................................12
4.4.4 Pressurization delay time coefficient ..................................................................................................12

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4.4.5 Low and high pressure limits..............................................................................................................12
5 TECHNICAL SPECIFICATIONS .....................................................................................................................13
5.1 Technical data...........................................................................................................................................13
5.2 Connections ..............................................................................................................................................14
5.3 Symbols.....................................................................................................................................................14
6 SPARE PARTS................................................................................................................................................14
2 APPENDICES

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CONTROL CENTER ST-1100i
1 GENERAL DESCRIPTION
ST-1100i is a microprocessor-based control center for SAFEGREASE and SAFEOIL lubrication
systems. The center is designed for controlling single channel lubrication systems. ST-1100i
controls lubrication according to the desired settings and lubrication events can be monitored at
the control panel and center cover LED-signals.
Lubrication programming, alarm acknowledgements and lubrication event monitoring can be
performed via both the control panel and the LED-signals.
2 DESIGN
Note Numbers in brackets refer to part numbers in the drawing 461543A.
ST-1100i Control Center main switch is located (pos. 1) at the bottom edge of the center casing.
There is a green power supply LED-signal (pos. 2) which is also the extra lubrication start
button. There is also a red alarm LED-signal (pos. 3) which is also the alarm acknowledgement
button. Center Control panel (pos. 4) is located inside the casing.
2.1 Cover
2.1.1 LED-signals
Signal Description
Power Green signal is lit, when power is on.
Alarm Red signal is lit, when control center has received an alarm that has not been
acknowledged.
2.1.2 Buttons
Extra lubrication
Button can be used to launch extra lubrication into the system.
The button is located at the center cover (Power LED signal).
Alarm acknowledgement
This button can be used to acknowledge an alarm after the problem causing the alarm has
been resolved.
The button can also be used to stop the system pressurization.
The button is located at the center cover (Alarm LED signal).
Pushing the button results in red LED signal being lit (signal testing).

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2.2 Control Panel
2.2.1 General
Control panel is located inside the casing. Control panel has a 6-character display, three
buttons and the input/output LED signals. The display and buttons can be used for setting the
default values for lubrication program and for turning on manual control.
2.2.2 Display
The control panel has a 6-character 7-segment display.
The display has been divided into two groups
•2-character value display gives the phase or value code
•4-character time display gives the value corresponding to the code
Time display
When time display is showing a time value, the decimal point blinks at intervals of 5 seconds.
Regardless of the code, time is always displayed the same way and as accurately as possible.
Time displayed Display format Example
0 s – 99 min 59 s MM.SS 12 min 34 s = 12.34
100 s -999 min 59 s MMM.S 123 min 45 s = 123.4
1000 min – 999 min MMMM. 1234 min = 1234.
> 9999 min 9999. 12345 min = 9999.
2.2.3 Buttons
Button Description
Setting/Pressure In Setting mode and while entering the password, button can be used to
change the displayed value with arrow keys.
Button can be used to accept transferring into manual operation, if the
value at the display is the code for manual operation. In manual
operation mode, pushing the button runs the function selected at display.
In pressure transmitter use, button can be used for browsing the
pressurized line pressure readings in normal and manual operation
modes.
ÐButton can be used for scrolling the next display below.
In Setting mode and entering password, button can be used for
decreasing the displayed value, if the Setting/Pressure button is
pressed down.
ÏButton can be used for scrolling the next display above.
In Setting mode and entering password, button can be used for
increasing the displayed value, if the Setting/Pressure button is pressed
down.

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2.2.4 LED-signals
Signal Description
PRESSURE, LINE 1 Line 1 pressure control status
In pressure switch operation, the signal is lit, when the switch is
closed.
In pressure transmitter operation, the signal is lit when pressure
exceeds the set high level and is turned off, when the pressure goes
below the set low limit.
PRESSURE, LINE 2 Line 2 pressure control unit status
As above.
LOW LIMIT Lubricant container low limit. Signal is lit, when the container is
empty - which means that the low limit switch is closed.
INTERLOCKING Lubrication point operation information. Signal is lit, when the
lubrication point is not in operation (= no interval calculated) – which
means that the Interlocking switch is closed.
LINE 1 Line 1 control. Signal is lit, when control is switched on.
LINE 2 Line 2 control. Signal is lit, when control is switched on.
PUMP Pump control. Signal is lit, when pump is in use - which means that
control is switched on.
ALARM Alarm. Signal is lit, when center has received an alarm and it has
not been acknowledged.
OK Signal is blinking, when the electronic system is working without any
problems.

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3 OPERATION
3.1 Normal mode
3.1.1 Phase codes for normal mode and alarm mode
When control center is in normal or alarm mode, the phase code corresponding to the program
phase is shown on the value display.
Phase code Phase description Time display
I Center is counting lubrication interval (Interval
counting) Interval duration
P Center is pressurizing the system (Pressurizing) Pressurization time
used
L Interlocking switch is closed (Locked) Locking time used
AL Lubricant container low level limit (Alarm, Low
level) Alarm time used
AP Pressure alarm (Alarm, Pressurizing) Alarm time used
Ed Extra delay time for grease lubrication system
pressure switch operation pressurization (Extra
delay)
Delay time left
dC Pressure discharge waiting time in pressure
transmitter operation
(disCharge)
Discharge time used
CL Center is closed (maximum pressurization time =
0)
(Closed)
Closed status duration
AE Electronics error alarm
(Alarm, Electronics) Error code
Interval counting
Center is always counting interval time, except when
•center is in alarm mode or turned off
•Interlocking switch is closed
•center is closed (maximum pressurization time = 0)
Pressurization extra delay time
Pressurization extra delay time is used, when grease lubrication systems (SG1 and SG2) are in
pressure switch mode.
Pressurization extra delay time is the minimum time between two pressurization phases. When
the delay setting prevents pressurization, there is phase code Ed in the value display and time
display shows the delay time left.

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Pressure discharge
In pressure transmitter operation, line pressure discharge is measured and new pressurization
can be started only after pressure in all lines is below the set low limit value.
When center is waiting for pressure discharge completion, there is a phase dC in the value
display and time display shows the spent discharge time. Center goes into alarm mode, if the
discharge time is longer than interval time (= lubrication time/2).
3.1.2 Normal mode displays
Buttons Ïand Ðcan be used to browse the normal mode displays which show the lubrication
program set values and to transfer into manual control.
Value display codes change in the following order when Ï-button is pressed and vice versa,
when Ð-button is pressed.
Display codes Description
HL Manual mode
(Hand Lubrication)
CC Lubrication cycle counter
(Cycle Counter)
LC Lubrication cycle set value
(Lubrication Cycle)
LP Maximum pressurization time set value
(Lubrication, Pressurization time)
Ld Lubrication delay time, total duration
(Lubrication delay)
Code is used only in pressure switch operation
Lo Low limit pressure set value
(Low limit pressure)
Code is used only in pressure transmitter operation
Hi High limit pressure set value
(High limit pressure)
Code is used only in pressure transmitter operation
LF Center function mode (configuration settings)
(Lubrication, Function)
PU Pressure display unit (configuration settings)
(Pressure Unit)
Pr Pressure monitoring unit (configuration settings)
(pressure switch operation/pressure transmitter operation)
(Pressure monitoring unit)
PASS Entering password
(PASSword)
Code shows in time display

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Configuration settings
Note Configuration settings should be changed only in connection to system
changes. These changes are usually implemented by the supplier.
Configuration mode requires a password.
Table 1. Center operation modes
Time display code Selected operation mode
SG1 single line grease lubrication system
SG2 dual line grease lubrication system
SG2E dual line grease lubrication system, pressure maintaining function
OS oil lubrication system
Display pressure unit should be either bar or psi.
Pressure monitoring unit type can be either pressure switch (S) or pressure transmitter (P).
3.1.3 Line pressure displays
In pressure transmitter operation, line pressure displays can be selected with
Settings/Pressure button. Pressing the button will show the line 1 pressure display first.
Another press will show line 2 pressure display and if there is no line 2, program returns back to
display phase code. From line 2 pressure display program returns to display phase code by
pressing Settings/Pressure button.
The lines selected in pressure display are presented in the value display as codes P1 or P2.
The pressure in the selected line is displayed in time display.
3.1.4 Returning to normal mode
Program returns to display program phase code (normal or alarm mode) in the following cases
1. Settings/Pressure or arrow button was last pressed more than three minutes ago.
2. both arrow buttons are simultaneously pressed down for 3 seconds
3. Ð-button is used to browse into phase code display
4. center is restarted

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3.2 Extra lubrication
Extra lubrication can be launched by pressing the Extra lubrication button located on the cover
Led signal Power. Lubrication is launched, if the center is not currently pressurizing the system,
in alarm mode or turned off.
In dual line grease lubrication system (SG2) both lines are pressurized once. In automatic
pressurization mode, the first line is pressurized first.
In single channel grease lubrication system (SG1) the line is pressurized twice.
In grease lubrication systems (SG1 and SG2)
•the line equipped with a pressure switch has a delay between pressurization phases.
Phase code Ed is displayed in value display and time display shows the delay time left
•the second pressurization phase in pressure transmitter operation is started, when the
pressure in the lines goes below the set low limit value. Value display shows waiting time
phase code dC and time display indicates the pressure discharge time spent.
In oil lubrication systems (OS) line is pressurized once.
Interval counter is reset when the last pressurization is started which means that the next
automatic mode pressurization is performed always according to lubrication cycle after extra
lubrication.
3.3 Manual control
Manual control mode can be transferred into by selecting the phase code HL into the value
display with the arrow buttons and by pressing Settings/Pressure button after that. Then value
display shows code HL and time display shows time 0.00; line and pump controls have not
been connected.
Note It is not possible to transfer into manual control mode, if pressurization is
being performed currently or center has triggered a low limit alarm.
Manual control mode can be browsed with buttons Ïand Ð. The selected function at the
display is run by pressing Settings/Pressure button.
Table 2. Manual control mode functions
Time display code Function
L1 line 1 line control connection
L2 line 2 line control connection
LOFF line control disconnection
PU-S pump start-up through switch control
PU-F pump start-up, forced
POFF pump off function
OFF transferring out of manual control mode
Note Oil lubrication system can use only forced control.

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Manual operation
1. Connect line 1 or 2 line control by means of L1 or L2 function
2. Start pump by means of PU-S or PU-F function. Program does not start the pump, unless
line control is connected. Time display shows pumping time.
3. Pump can be stopped by pressing Alarm acknowledgement button on the cover or by
selecting code POFF at the display and by pressing Settings/Pressure button.When
pump stops, the pumping time used remains on the display. Line control remains
connected.
Switch control
•in the pressure switch operation the pump stops when the switch is closed and re-starts
when the switch is re-opened
•in the pressure transmitter operation the pump is stopped when pressure reaches the set
high limit and is re-started again when pressure goes below the high limit value
Forced control
•pump operates regardless of the pressure control unit status
Pumping time
•Pumping time always starts at zero status, when pump is started.
•When switch control is being used, time value is not reset, when the pump is stopped and
started through the pressure monitoring unit control system
Transferring out of manual control mode
One can transfer out of Manual control mode and into Automatic mode by selecting the code
OFF into the value display and by pressing Settings/Pressure button after that. System also
returns automatically to Automatic mode, if 60 minutes has gone since Manual control was
taken into use or if control center triggers a low limit alarm. Also re-starting the center returns it
to Automatic control mode.
When Manual control mode is turned off, all line controls and pump control are disconnected.
Interval time is counted also during Manual control mode. In Automatic control mode, the center
starts pressurization, when the set delay time from the termination of Manual control mode has
expired (pressure switch operation) or when pressure in the pressurized lines is below the set
low limit value (pressure transmitter operation).
3.4 Lubrication cycle counter
All lubrication cycles performed by the center can be displayed by selecting code CC in the
value display.
In grease lubrication system counter reading unit is added after one lubrication cycle, in other
words after every other pressurization. In oil lubrication system each pressurization is added on
to the counter.
3.5 Power failure
The set values and program status are preserved in the center memory also during power
failures. After power is back on, the center will resume from the status it was before power
failure occurred. Possibly terminated pressurization event is re-started for the same line.
Interval time is not counted during power failures.

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3.6 Alarms
The center is in alarm mode, when the red Alarm signal is lit.
3.6.1 Low limit alarm
The center triggers a low limit alarm, pauses pressurization and goes into alarm mode, if the
lubricant container is empty which means that the low limit switch is closed. The value display
shows phase code AL and time display the spent alarm time. The same line will be pressurized
again, when low limit switch is open and the alarm has been acknowledged by pressing the
Alarm acknowledgement button on the center cover.
3.6.2 Pressure alarm
The center triggers a pressure alarm and goes into alarm mode, if the line is over-pressurized
when pressurization phase is starting or if the pressure in the line pressurized does not get
sufficiently high during pressurization time. The value display shows phase code AP and time
display the spent alarm time. In dual line grease lubrication systems, the spent alarm time and
the line that caused the alarm are displayed in turns on the time display.
Pressure switch operation
In Pressure switch operation, pressure alarm is triggered, if the switch is closed, when
pressurization is started. The same line will be pressurized again, when pressure switch is open
and the alarm has been acknowledged by pressing the Alarm acknowledgement button on the
center cover.
Pressure alarm is triggered also, if the pressure switch for the pressurized line does not close
within the set maximum pressurization time. The same line will be pressurized again, when the
alarm has been acknowledged by pressing the Alarm acknowledgement button on the center
cover.
Pressure transmitter operation
In Pressure transmitter operation, pressure alarm is triggered, if the pressure in the line is
above the set low limit, when pressurization is started. The same line will be pressurized again,
when pressure level is below the low limit value and the alarm has been acknowledged by
pressing the Alarm acknowledgement button on the center cover.
Pressure alarm is triggered also, if the pressure in the pressurized line does not reach the set
high limit within the set maximum pressurization time. The same line will be pressurized again,
when the alarm has been acknowledged by pressing the Alarm acknowledgement button on
the center cover.
3.6.3 Power failure alarm
During power failure, alarm relay is in alarm mode. Alarm is automatically acknowledged, when
the power is back on.
Note Alarm signal on the center cover is not lit during power failure alarm.

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3.6.4 Electronic system error alarm
The center triggers an electronic system error alarm and goes into alarm mode, if the test
program ran at the start-up detects any errors in the electronic system. The value display shows
phase code AE and time display the spent alarm time.
Error code Description
EP Program memory check sum error
EE setting information check sum error
Df alarm triggered by program execution monitor circuit
Alarm can be acknowledged by pressing the Alarm acknowledgement button on the center
cover. If this alarm recurs at the next start-up, please contact the center manufacturer.
4 SETTINGS
4.1 General
Center settings can be divided into two groups:
•Set values
•Configuration settings
Set values are lubrication system values, for example lubrication cycle and maximum
pressurization time. Set values can be changed in Settings mode.
Configuration settings determine the center functions according to the lubrication system. These
settings are usually factory settings and there should not be any reasons to change them during
operation.
All settings are password-protected.
4.2 Entering settings
1. Select the code for the setting to be changed at the display.
2. Press Settings/Pressure button and keep it down.
3. Use arrow buttons to select the desired setting at the display.
4. Release Settings/Pressure button and the new setting is stored in the system memory.
Note If the arrow button is pressed down continuously, settings will change at the
display at accelerating speed.

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4.3 Entering password
Select code PASS at time display.
Enter correct password using Settings/Pressure and arrow buttons.
When Settings/Pressure button is released, the center goes into Setting mode. The codes
show now decimal points, for example C.C.
Note Set value password is 2.
4.4 Setting mode
Setting mode displays showing the lubrication program set values can be browsed by means of
arrow buttons.
Value display codes change in the following order when Ï-button is pressed and vice versa,
when Ð-button is pressed.
One can leave Setting mode but browsing to code PASS by means of Ð-button.
Display code Description
C.C. Lubrication cycle counter
(Cycle Counter)
L.C. Lubrication cycle set value
(Lubrication Cycle)
L.P. Maximum pressurization set value
(Lubrication, Pressurization time)
L.d. Lubrication delay time coefficient
(Lubrication delay)
Code is used only in pressure switch operation
L.o. Low limit pressure set value
(Low limit pressure)
Code is used only in pressure transmitter operation
H.i. High limit pressure set value
(High limit pressure)
Code is used only in pressure transmitter operation
4.4.1 Lubrication cycle counter
Code C.C. shows the lubrication cycle counter reading at display.
The counter can be reset by setting the counter value to zero using Settings/Pressure and
arrow buttons. The only changeable counter setting is to reset the counter.

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4.4.2 Lubrication cycle
Code L.C. shows the lubrication cycle set value at display.
Enter desired lubrication cycle value using Settings/Pressure and arrow buttons.
The time can be set within 0 min 00 s -9999 min. In grease lubrication systems, pumping is
started twice during one cycle. In Oil lubrication system pumping is started once during one
cycle.
The set value will be immediately regarded as the new lubrication cycle value and the time
already spent in the cycle is counted as new interval time.
4.4.3 Maximum pressurization time
Code L.P. shows the maximum pressurization time set value at display.
Enter desired value using Settings/Pressure and arrow buttons.
The time can be set within 0 min 00 s -999 min.
The center can be shut off by setting the maximum pressurization time to 0 s. The value display
will show a phase code CL. When the center is closed, only manual control operation is
possible.
4.4.4 Pressurization delay time coefficient
This feature is available only in pressure switch operation.
The value display code L.d. shows the value set for the coefficient.
Enter the desired value using Settings/Pressure and arrow buttons.
This value can be within the range 0.0 - 99.9.
Delay time calculation formulas
Formula 1. Delay time
Delay time = Set maximum pressurization time * Delay time coefficient
Formula 2. Delay time (max.)
Delay time (max.) = Set lubrication cycle value/2
An example: The maximum pressurization time is at 3 min. The desired delay time is 10 min.
Set the delay time coefficient to 10min / 3 min = 3.3.
4.4.5 Low and high pressure limits
Low and high pressure limits are used only in pressure transmitter operation.
The value display code L.o. tells the set value for low limit and the code H.i. tells the set value
for high limit.
Enter desired values using Settings/Pressure and arrow buttons.
These limits can be set within the range of 0–160 bar (0–2320 psi.).

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5 TECHNICAL SPECIFICATIONS
5.1 Technical data
Value Range Unit Description
t -20…+60 °C operation temperature
Uin 230 ±15%, 50/60
115 ±15%, 50/60 V AC, Hz V AC, Hz Power input, 160 VA max. Voltage range preset at factory and indicated in
the center name plate.
Uout 24 V DC Control voltage, unregulated 5 A max.
The internal power supply for controlling the
system.
F1 1 (230)
2 (115) AT (V AC) AT (V AC) Power input fuse, 20x5 mm glass tube fuse, slow
F2 5 AT Control voltage fuse, 24 V for I/O-voltage, 20x5
mm glass tube fuse, slow
F3 2 AT Electronic system fuse, 15 V, 20x5 mm glass
tube fuse, slow
200 x 300 x 120
(lxkxs) mm Steel casing
IP65 Protection classification
Time settings
Lubrication cycle value can be set within 0 min 00 s – 9999 min.
Maximum pressurization time can be set within 0 min 00 s - 999 min.
All time settings are password-protected.
Power failure protection
Set values and program status at the power failure are stored in the EEPROM memory, no
batteries.

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5.2 Connections
All connections are measured for 2.5 mm2conductor cross section area.
Input
•pressure switch, 2 pcs, closing pushbutton
or pressure transmitter, 2 pcs, 4–20 mA / 0–250 bar, 2-wire conductor
•Lubricant container low limit switch, closing connection
•Interlocking, lubrication point in operation = switch open
Output
•Line, 2 pcs, closing pushbutton, connects 24V / 1A max.
•pump control, closing pushbutton, connects 24V / 5 A max.
•Alarm, two voltageless exchange switches, loading 50V / 1A max.
Cable channels in the casing
•5 channels for 7–10 mm cable diameters
•1 channel for 10-14 mm cable diameters
5.3 Symbols
ST-1100i-xxx-U Abbreviation Description
ST: ST SafeTimer
1100i: 1100i model, 1-channel control center
xxx: FIN language, Finnish
ENG language, English
SWE language, Swedish
GER language, German
FRA language, French
ITA language, Italian
RUS language, Russian
SPA language, Spanish
POR language, Portuguese
NOR language, Norwegian
HOL language, Dutch
U: no symbol power input, 230 V AC ±15% 50/60 Hz
U power input, 115 V AC ±15% 50/60 Hz
6 SPARE PARTS
See ST-1100i control center spare parts (drawing no. 461544A)