SKF 86535 User manual

Single line and progressive
lubrication system controller
Model 86535
Date of issue June 2015
Publication number 404416C
Section C8
Page Number 350C
Installation and user guide

Safety
Carefully read and observe operating
instructions before installing and operating
controller.
Table of contents
Explanation of safety signals ....... 2
Safety ......................... 2
Description ..................... 3
PC requirements ................. 4
Software installation ............. 4
Controller preparation ............ 5
Controller configuration ........... 6
Controller history ................ 16
Firmware update ................ 17
Controller installation ............. 18
Field connections ................ 19
Controller must only be installed,
maintained, and repaired by persons
familiar with these operating
instructions.
Do not attempt to install, use, or
troubleshoot prior to fully understanding
all safety and operational instructions.
WARNING
!Notice
Local safety regulations regarding
installation, use and maintenance must
be followed.
Explanation of safety
signals
Indicates hazardous situation which, if
not avoided, could result in minor or
moderate injury.
CAUTION
Indicates hazardous situation which, if
not avoided, may result in death or
serious injury.
WARNING
Indicates hazardous situation which, if
not avoided, will result in death or
serious injury.
DANGER
Safety instruction sign indicates specific
safety-related instructions or
procedures.
SAFETY INSTRUCTION
Safety alert symbols identify potential
physical injury hazards. Obey all safety
messages below this symbol to avoid
possible injury or death.
2

!Notice
Use of end of line pressure
transducers recommended. Transducers
allow for detection of pressurization
failures, such as injector cycle and
injection venting failure.
Description
Functionality
LMC 101 controls both single line and
progressive lubrication systems. While
designed for off-the-road and mobile
equipment use, controller can be used for
any low voltage lubrication application.
Several controller features include:
• 12 and 24 V DC systems
• Time or controller mode
• Single line and progressive systems
• Various alarm condition settings,
including:
–cycle frequency
–alarm triggers
• Programming, data logging, and
reporting, including:
–system resets
–downloads to controllers
–lubrication activity
–lubrication cycles
–alarms.
Controller must be programmed via USB
connection to PC.
Timer mode
• In timer mode, lube cycle ends when
pre-assigned time has expired.
!Notice
Steady alarm light indicates
controller will attempt another
lubrication cycle.
Blinking alarm light indicates no
more lube cycles be attempted until fault
is corrected.
Controller mode
• In controller mode, lube cycle ends when
pressure switch, pressure transducer, or
piston detector actuates.
Single Line system
In single line systems:
• Pressure switches or pressure
transducers can be installed at pump and/
or end of supply line.
• System allows pressure to dissipate to
end of supply line once pressure at pump
is reached.
Enclosure lid
Enclosure lid features:
• Manual lubrication push button.
• Four LEDs:
–Power on/run
–Pump on
–Low level fault
–System fault (alarm)
Table 1
Product specification
Input voltage 12 V DC and 24 V DC -20%/ +30%
Current consumption 60 ma (less external load)
Pump relay contact 20 A at 30 V DC
Vent relay contact 2 A at 30 V DC
Alarm relay contact 2 A at 30 V DC
Enclosure rating NEMA 12
Temperature range –40 to 150 °F (–40 to 65 °C)
Net weight 2 lbs. (0,9 kg)
Off time (adjustable) 15 seconds to 99 hours
On time (adjustable) 15 seconds to 99 hours
Lubrication system Single line and progressive
Enclosure size 8.25 x 5 x 3.50 in. (20,9 x 12,7 x 8,9 cm)
Mounting dimensions 8.75 x 3.75 in. (22,2 x 9,5 cm)
Table 2
Parts list
Item no. Description Part no. Quantity
LMC USB Cable Kit 86505 1
3

PC requirements Software installation
!Notice
Do not install or run LMC
software on server-level operating
systems.
!Notice
Controller software needs 32-bit
version of .Net framework to function.
32-bit version of .Net will operate on
64-bit PCs.
!Notice
Do not install LMC 101 software
before confirming computer meets all
requirements in PC requirements
section on this page.
Requirements
1 800 x 600 display (1024 x 768
recommended).
2 Keyboard and mouse (or other pointing
device).
3 USB 2.0 port and standard cable with
full size B-type connector
4 Microsoft .Net Framework 4.0 client
installed.
5 50MB of available hard drive space
(after .Net 4.0 client installed).
!Notice
If PC does not have Microsoft .Net
Framework 4.0 client installed, confirm
PC meets these requirements before
downloading .Net 4.0 client to PC:
• Processor: 1 GHz
• Memory: 512 MB
• Hard drive: 1.5 GB
• Operating systems:
· Windows 7
· Windows 8
If PC meets requirements, visit http://
www.microsoft.com/en-us/download/
details.aspx?id=17851 and install .Net
software before proceeding.
!Notice
Controller must be connected to
a PC that meets these requirements in
order to be configured.
1 Visit http://www.lincolnindustrial.com/
products/als.aspx and click link labelled
LMC 101 PC Software.
2 Download PC software installation files
from website.
3 Follow installation on-screen
instructions until installation is
successful.
4

Controller preparation
1 Disconnect power supply to LMC 101.
2 Remove LMC 101 cover to expose
printed circuit board.
3 Connect USB cable from PC to USB port
on circuit board.
!Notice
When configuration is complete,
remove USB cable from controller and
re-attach cover before using controller.
!Notice
LMC 101 software must be
installed on a PC with a USB port prior
to proceeding in this section.
4 Wait for Run light to stop blinking before
proceeding.
5 On PC, double-click LMC 101 software
icon.
6 Follow instructions in Controller
configuration section on page 6 to
configure and customize controller.
!Notice
When USB cable is connected,
Run and Power lights on enclosure lid
will light up, with Run light blinking.
5

Fig. 2
1 From main screen, click Program
Controller button.
2 LMC 101 configuration window
2.1 In Customer field, enter name of
your organization.
2.2 In Location field, enter either
name of your location, name of
your department, or other name
that will uniquely identify system
that will be controlling software.
Controller
configuration
!Notice
LMC 101 can only be configured
via USB cable to a PC that meets all PC
requirements listed on page 4.
!Notice
Customer and Location fields are
stored on PC and on controller. If
wanting to track pump history and
activity from multiple controllers,
determine a naming convention prior to
proceeding.
Fig. 1
6

Menu bar
3 On menu bar across top of window
(fig. 2), three options are displayed -
File, Clock, and Units.
3.1 Clicking on File displays:
3.1.1 Open file - allows user to
select existing LMC 101
account settings for editing
and/or downloading to
another controller.
3.1.2 Save file - creates and/or
saves all LMC 101 settings to
PC.
3.1.3 From controller - uploads
settings from controller to
PC.
!Notice
Manual adjustment of internal
clock is not recommended if historical
data tracking is desired.
!Notice
USB port number must be
selected prior to completing step 3.1.3.
3.1.4 To controller - downloads
selected or saved account
settings to controller.
3.1.5 Exit - closes LMC 101
configuration window.
3.2 Clock adjusts controller’s internal
clock.
3.2.1 Click sync time to PC button
(fig. 3).
3.3 Units opens a popup window that
defines units in English or Metric.
3.3.1 English mode will display
units in psi.
3.3.2 Metric mode will display
units in bar.
Fig. 3
7

Fig. 4
Left side menu
In left side menu, four options will be listed
- Location, System, Single-line, and
alarms. Step 2 on page 6, covers default
selection location.
4 System displays:
4.1 System type - drop menu to
define system as:
· Single-line, or
· Progressive
4.2 Pause time - defines pause time
between lubrication cycles.
4.3 Maximum pumping time -
defines amount of time each pump
will send lubricant.
4.4 Prelube mode - controls pre-
lubrication activity (see step 5 on
page 9).
4.5 Pulse active checkbox - activates
pump pulsing option during pump
cycling, as defined by pulse time
interval text box.
4.6 Pulsing time interval - defines
amount of time between pump
pulses.
!Notice
If system is progressive, skip to
step 1 on page 14.
!Notice
Pulse air flow causes control
board vent relays to pulse on and off.
!Notice
Pulse time controls frequency of
pulse air flow.
8

Fig. 6
Fig. 5
6.1 Options controlled by these radio
buttons:
6.1.1 Timed – select if using time
to control pump activity (if
selecting this option, skip to
step 10 on page 13).
6.1.2 Pressure switch – select if
using pressure switch
measurement at pump to
end lube cycle signal (if
selecting this option, proceed
to step 7 on page 10).
6.1.3 Pressure transducer –
select if using transducer
pressure measurement at
pump to end lube cycle (if
selecting this option, skip to
step 8 on page 11).
5 Prelube drop menu defines lubrication
cycling option upon controller power up.
·Always – a prelube cycle will always
occur during power up.
·After 3hr off – a prelube cycle will
only occur when power has been off
for longer than 3 hours.
·Never – a prelube cycle will not occur
during power up.
6 Clicking on single line will display timer
or controller mode radio buttons.
9

Fig. 7
7 Selecting pressure switch radio button
activates:
7.1 End of line – allows use of a
second pressure switch at end of
lube supply line to complete
lubrication cycle.
7.2 Pressure hold time – allows
lubricant pressure to dissipate in
supply line after an elapsed
amount of time.
!Notice
Pressure hold time option is only
available when not using an end of line
pressure switch.
A pressure switch or transducer must
still be used at pump in End of Line
systems to prevent pressure build up.
WARNING
10

Fig. 8
8 Selecting pressure transducer radio
button activates:
8.1 End of line – allows use of a
second pressure transducer at end
of lube supply line to complete a
lubrication cycle.
!Notice
Pressure hold time option only
available when not using an end of line
pressure transducer.
!Notice
A pressure switch or transducer
must still be used at pump in End
of Line systems to prevent pressure
build up.
8.2 Pressure Hold Time – Allows
lubricant pressure to dissipate in
supply line after an elapsed
amount of time.
8.3 Transducer radio button:
·1 to 6 V Transducer - allows use of a
1 to 6 V transducer.
·4 To 20 mA transducer – allows use
of a 4 to 20 mA transducer.
8.4 Max transducer pressure – sets
maximum pressure rating of
transducer. Software allows for
input range of:
· 0 To 4000 psi (Imperial units setting)
· 0 To 275 bar (Metric units setting)
!Notice
If pressure transducer option is
selected, a pressures option will display
on left side menu.
11

Fig. 9
9 Clicking on pressure displays:
9.1 Pressure to insure injector vent
– At start of lube cycle, pressure
reading from transducer must be
at or below this level. If using an
End of Line pressure transducer,
reading is taken from this
transducer.
!Notice
Option will only display in left side
window if Pressure Transducer option
selected.
9.2 Pump pressure at which lube
cycle ends – If only using one
pressure transducer, lube cycle will
end at this setting.
!Notice
For step 9.2, if using an End of
Line pressure transducer, pump will
stop at this pressure level to allow
dissipation of pressure in supply line.
Pump will restart once this pressure
level drops below 25% of this setting.
9.3 Line pressure at which lube cycle
ends – sets End of Line pressure
transducer limit to end lubrication
cycle.
12

Fig. 10
10 Clicking on alarms displays:
10.1 Low level fault radio buttons –
indicates that reservoir is low or
empty.
·No more lube cycles after low level
alarm – no more lube cycles will
occur after a low level alarm.
·Continue to allow lube cycles after
low level alarm – lube cycles will
continue after a low level alarm.
·Limited number of lube cycles after
low level alarm – a set number of
lube cycles will occur after a low level
alarm.
10.2 Pressure fault – indicates that a
pressure fault has occurred.
·No more lube cycles after pressure
alarm – no more lube cycles will
occur after a pressure alarm.
·Continue to allow lube cycles after
pressure alarm – lube cycles will
continue after a pressure alarm.
·Limited number of lube cycles after
a pressure alarm – a set number of
lube cycles will occur after a low level
alarm.
10.3 Alarm output setting for both
alarm relays
·Relay contact closes on alarm –
alarm detection will close relay.
·Relay contact opens on alarm –
alarm detection will leave relay open.
13

Fig. 11
Progressive systems
1 Clicking on system displays:
1.1 System type - drop menu that
defines system for controller as:
· Single-Line
· Progressive.
!Notice
Within this time span, pressure
switch, pressure transducer, or proximity
switch must indicate end of cycle. Failure
to indicate end of cycle within this time
span will result in an alarm.
1.2 Pause time – sets time spans
between lube cycles.
Range: 15 seconds to 99 hours.
!Notice
If system is single line, return to
step 1 on page 8.
1.3 Maximum pumping time -
amount of time that pump will be
allowed to remain active.
Range: 15 seconds to 99 minutes.
1.4 Prelube drop menu defines
lubrication cycling when controller
powers up. Available options are:
·Always – a prelube cycle will always
occur after power up.
·After 3hr off – a prelube cycle will
only occur when power has been off
for more than 3 hours.
·Never – a prelube cycle will not occur
after power up.
1.5 Pulse active checkbox - activates
pump pulsing option during
cycling, as defined by input time
interval.
!Notice
Pulse air flow causes vent relay
on control board to pulse on and off.
1.6 Pulsing time interval - defines
amount of time between pump
pulses.
!Notice
Pulse time controls frequency of
pulse air flow.
14

Fig. 13
Fig. 12
2 Clicking on Progressive will display
Timer and Controller radio buttons:
2.1 Timed – Amount of time that
pump will be on.
2.2 Proximity switch – proximity
switch actuation ends lube cycle.
2.3 Proximity - Number of proximity
switch actuations per cycle.
!Notice
Proximity switch must actuate
number of times entered in Pulses box
during each lube cycle. Failure of
controller to detect number of
actuations within defined maximum
pumping time triggers alarm.
!Notice
For instructions on Alarm
features, refer to step 10 on page 13.
15

Fig. 15
Fig. 14
1 From main screen, click history button.
The controller history window will
display (fig. 15).
2 Each button on right side of window will
produce a different type of history
report. For all reports:
· each event will be time and date
stamped.
· all data can be transferred by using
copy (Ctrl+C) and paste (Ctrl+V).
· a maximum of 72 event will be
captured.
Controller history
!Notice
If more than 72 events are
present, only the most recent 72 reports
will be captured. Older events will not be
included.
2.1 System button – captures date
and time for any system reset,
including each time:
· a controller powers up.
· a new configuration is saved to a
controller.
2.2 Lube cycles button – captures
date and time for each successful
lube cycle.
2.3 Alarms button – captures date
and time for each alarm that
prevented cycling.
2.4 Counters button - captures counts
for:
· All attempted lube cycles
· All successful manual lube cycles
· All alarm events caused by pressure
· Low level alarms
· Total amount of time that pump has
been on.
2.5 Clear counters button - resets all
alarm counts to zero.
16

Fig. 16
Firmware update
1 Remove power from LMC 101.
2 Remove controller cover.
3 Attach LMC 101 to PC via USB cable.
Controller’s Run light will blink for
13 seconds.
4 Launch Firmware Updater Utility on PC.
Fig. 16 will display.
!Notice
Only perform these steps when
notified of firmware updates.
!Notice
Firmware update utility must
connect to controller within 13 seconds.
·If light continues to blink,
connection was successful.
Continue to next step.
·If light stops blinking, connection
was unsuccessful. Repeat
steps 1-4 until light continues
blinking.
5 Click Find button.
6 Navigate to latest code file (.Hex file).
7 Highlight code file and click open.
8 Click Update Firmware button.
9 Wait until firmware update utility
finishes.
10 Unplug USB cable from controller and
reattach controller cover.
11 Reconnect power to controller and
return to service.
17

Fig. 17
Controller installation
and field wiring
Connect field wiring to the LMC 101 by
following the wiring diagram
(† figs. 19-22, pgs. 20-23) appropriate to
your single-line and progressive systems.
Refer to the diagrams for specific
information on power connections, inputs,
outputs, and connection polarity.
1 Route the 86535 connection cables
through the cable glands (4 and 5) on
the bottom of the enclosure (8).
!Notice
Terminals for signal inputs (1),
for supply (2), and actuator lines (3) are
located on control PCB (fig. 17).
Refer to wiring diagrams for detailed
information on wiring connections
(† figs. 19-22, pgs. 20-23).
!Notice
Relieve tensile force on cables
from outside of housing.
1
3
2
5
7
6
8
9
10
4
Callout Description Callout Description
1 Control output (actuator)
4 relay outputs
1 electronic output
5 Screw
6 Button cell lithium battery, 2032
7 USB type B
2 Input power and pump power 8 Cable gland for control inputs and outputs 1/2 in. (12,7 mm)
diameter
3 3 wire initiators up to 24 volts (PNP)
2 wire initiators, residual voltage < 5 volts
9 Enclosure
4 Front cover 10 Cable gland for voltage supply 1/2 in. (12,7 mm) diameter
2 Refer to wiring diagram and make
electrical connections.
3 Program the controller.
4 Place the front cover (4) onto the
enclosure (7).
5 Mount the controller using dimensions in
fig. 18.
18

Fig. 18
Dimensions
6.75 in.
171,5 mm
3.5 in.
88,9 mm
Ø 0.19 in.
4,8 mm
7.29 in.
185,2 mm
4.72 in.
119,9 mm
5.62 in.
142,8 mm
6.12 in.
155,5 mm
1.16 in.
29,464 mm
1.50 in.
38,1 mm
1.196 in.
30,37 mm
1.50 in.
38,1 mm
19

Fig. 19
Field connections - wiring diagram for single-line system using pressure switches
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1234
A
A
A B
M
DC
F
E
+
-
+
-
+
-G
H
I
J
K
L
Table 3
Key code for fig. 19 - single-line system using pressure switches
Callout Description Callout Description
APositive (+) to motor (from battery) GSystem alarm
BGround (-) to motor HReservoir low level
CGround (-) from battery IRemote manual lube
J Pressure switch at pump
DPositive (+) from battery KPressure switch at EOL (end of line)
EVent solenoid LUSB port
FLow level alarm
24V
VENT
SOLENOID
GND
2 1
1 2
4 3
LL FAULT
3 4 5 6
SYSTEM FAULT
7 8 9 10
SYSTEM FAULT
11 12 13 14
PRESSURE AT
PUMP
17 18 19 20
PRESSURE AT
EOL
21 22 23 24
MAN
LUBE
15 16
Outputs To
motor
From
battery
Inputs
Port
M
A
Wire
Power
source (+)
Motor Switch
Normal open
USB data port
Pressure Transducer
Switch
Normal closed
Alarm output
Solenoid Fuse - size
according to use
Ground (-)
Jumper1)
1) Jumper connects (+) battery power to positive terminal of alarm contact. Disconnect jumper for open contacts.
20