Service Guide

Centralized Lubrication System (CLS) Controller

The Alemite solid state CLS 1000 is a multi-use controller with the ability to be incorporated into various types of centralized lubrication systems. It can be used with multiple AC and DC voltages in systems requiring a system feedback principle (cycle or pressure switch) or in a timed on/off mode. The lubrication scheduled intervals can be initiated by time, machine cycle/strokes or manual run and programmed to provide a pre-lubrication cycle or reset to zero with no pre-lube at startup. It can be used with pneumatic, motorized and hydraulic operated pumps with either a continuous or pulsed operation for series progressive, parallel injector, parallel dual line, single line resistance, pump-to-point, spray systems, etc.

387780

Specifications

Enclosure: Plastic with Clear Cover, NEMA 4x, IP66 Display: LCD 2 Lines, 16 Characters per line Up to 4 digits per entry 3 LEDs Power (Green), Fault (Red), Lube (Yellow) Machine cycles counts shown in main display Input power, current consumption (less load): 85-135 V ac / 0.2 amp. 120-265 V ac / 0.1 amp 10-30 V dc / 0.4 amp External pump load: 12 Vdc 230 Vac, 50-60 Hz 10 amp relay output (external fused by user, matched to equipment used) Fault output load: 12 Vdc 230 Vac, 50-60 Hz 10 amp relay output (external fused by user,matched to equipment used) Ambient temperature range storage: -10 to 160 F (-23 to 71 C) Ambient temperature range operational: 0 to 120 F (-18 to 48 C)

Vibration Capable of withstanding 0.04 g2/Hz from 20 to 2000 Hz Wire size Removable terminal blocks for maximum 14 AWG wire. Terminal blocks may be removed by placing a flat screw driver in the slot at the back of the block and twisting. The blocks swing up and out. Reverse to attach. Switch Inputs There are three switch inputs: Lube Cycle, Machine Cycle Count and Manual Run. The circuitry supports dry contact or proximity switch options for the Lube Cycle and Machine Cycle Count inputs. Input (lube) Count rate 10 Hz max. (600 CPM) Lube Cycle/Machine Cycle/Manual Run switch inputs Dry contact, 24 Vdc, 2.5 mA max. Note: 24 Vdc is supplied by the CLS 1000 Programming: Lube off time - 1 to 9999 secs, mins, hrs, or counts Lube on time - 1 to 9999 secs, mins, hrs, or counts Timing accuracy 0.1% Machine cycle counts 0.5 99.5 by half counts Pump Continuous or Pulsed o Pulse off time 3 seconds fixed o Pulse on time 0 to 99 seconds Pre-lube power up mode can be programmed Program Entry 6 Push Buttons Menu, Enter and 4 Arrow keys

Alemite Corporation 167 Roweland Drive, Johnson City, Tennessee 37601 www.alemite.com

670864

Copyright 2006 bu Alemite, LLC This document contains confidential information that is the property of Alemite, LLC and is not to be copied, used, or disclosed to others without express written permission.

SER 387780 Revision (11-06)

SER 387780

Centralized Lubrication System Controller

CLS 1000 Service Guide Contents

General Description ............................................................................................................3 Operation .4 Modes of Operation- Set Up Mode (Overview).......5 Modes of Operation Set Up Mode (Programming)...5 Manual Run Mode .10 Wiring Connections 11 Supply Power Wiring Examples ...13 Pump Power/Control and External Alarm Wiring Examples ...15 Input Switch/Sensor Wiring Examples .18 General Wiring Examples ..23

Revision (11-06)

Alemite Corporation

Centralized Lubrication System Controller

SER 387780

General Description
Lubricant Dispensing The dispensing of lubricant can be scheduled and monitored using three key values. Idle Time This is the time between scheduled lubrication cycles as set up in seconds, minutes, hours or machine counts. Cycle Count This is the number of divider valve cycles to dispense the proper amount of lubricant. An end-of-cycle switch (limit, micro, or proximity switch) sends an electronic signal back to the Lube Controller, where the cycles or half cycles are counted. Alarm Interval This is the maximum time or machine counts allowed for a lubrication cycle to be completed. If this time or count is reached before the entered Cycle Count is reached, a fault condition is generated.

the CLS 1000. Please refer to Figure 1 as needed when reviewing the definitions.

Display and Key Definitions

Light Emitting Diodes The three LED's provide a quick view of controller status. POWER (Green) This LED indicates that power is applied to the Lube Controller. LUBE (Yellow) This LED indicates that the pump is on and lubricant is being applied. FAULT (Red) Indicates that a fault condition has been detected. The user can select to continue lubrication cycles or to stop them until the fault is corrected and/or cleared. Liquid Crystal Display The LCD provides operating status, operating instructions, setup information and fault information on 2 lines with up to 16-characters on each line. Along with the keys the display provides for easy set up and operation of the Lube Controller. Operator Key Pad The six operator keys provide the following for operator inputs. Left Arrow ( ) Moves a display selection to the left. Right Arrow ( ) Moves a display selection to the right. Up Arrow () Increments a selected digit up by one or selects an operation per indicated instructions. Down Arrow () Decrements a selected digit up by one or selects an operation per indicated instructions. ENTER Pressing the ENTER key will cause the Lube Controller to save the displayed data and transition to the next step.

Figure 1: CLS 1000 Lube Controller Displays and Keys A sketch of the front view of the CLS 1000 Lube Controller can be seen in Figure 1. The following description provides an overview of the components of

MENU This key allows the user to set up the controller's operation. It will command the Lube Controller to move between the Set Up and Auto Run modes.

Alemite Corporation

Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Operation
Power Up Operation When power is applied the Lube Controller will go to one of 3 operating states. Power Up (with no previous set up) If the Lube Controller is being operated for the first time the display shows: Alemite CLS 1000 No Setup Pressing the MENU key will cause the Lube Controller to go to the Set Up mode. See the section on Modes of Operation to see the setup sequence. Power Up (with lubrication cycle) The Lube Controller performs a lubrication cycle upon power up if that selection has been made during set up. The display shows: Lube XX.X counts or Lube Alarm off XXXX [alarm units] Power Up in Idle Time The Lube Controller starts the count for the idle period of the lubrication cycle if that selection has been made during set up. The display shows: Idle XXXX [off or idle units]

Revision (11-06)

Alemite Corporation

Centralized Lubrication System Controller

SER 387780

Modes of Operation
Set Up Mode (Overview) Pressing the MENU key will cause the Lube Controller to go to the Set Up mode. The Set Up mode allows the user to configure the CLS 1000 Lube Controller for a dedicated application. The configuration consists of units (counts, seconds, minutes, or hours) and the operating values. Set Up mode is also used to select pump output control (continuous or pulsed) and the desired function following an input power cycle or a fault condition. Arrow Keys Each operating value requires an entry of up to 4 digits. The digit to be modified will be underlined. To change the value of the underlined digit press the UP or DOWN arrow key to increment or decrement the underlined digits value. To move to another digit press the LEFT or RIGHT arrow key. Once another digit has been selected it will be underlined indicating that it will be modified if the UP or DOWN arrow key is pressed. Once the desired values have been selected for all digits: Press the ENTER key. Pressing the ENTER key performs two functions: It saves the value displayed in the field Moves the Set Up Mode to the next value or selection. During the Set Up process, if the desired value is already displayed, press the ENTER key. The value displayed will be saved. Moves the Set Up Mode to the next value or selection. SET UP MODE (Programming) Set Up Mode proceeds through the configuration steps in the following order. The words on the display are shown in quotes , for each step. Idle Units Idle units Counts or Seconds or Minutes or Hours This is the unit of measure of the delay between lubrications/cycles. Use the Up and/or Down arrow keys to select the desired units. Press the ENTER key to save the selected units and move to the Idle Time field.

Alemite Corporation

Revision (11-06)

SER 387780 Idle Time Idle time XXXX [idle units]

Centralized Lubrication System Controller

This is the number of units (Counts, Seconds, Minutes, Hours) between lubrications. Use the Up and Down arrow keys to modify the digit to the desired value. Use the Left and Right arrow keys to select between digits. Note that the underlined digit is the one being changed. Press the ENTER key to save the Idle (or Off) Time value and move to the Cycle Counts field. Cycle Counts Cycle Counts XX.X cycles When configuring the system to lubricate based on machine cycles this input will be the source of the machine cycle count. Enter the cycle count in the number of full cycles of the divider valve. If the application is using halfcycles then divide the number of half-cycles by 2 to determine the number of full cycles and enter that value. The default value for Cycle Counts is 01.0 or one divider valve cycle. The value 00.0 is a special case as described below. Use the Up and Down arrow keys to modify the digit to the desired value. Use the Left and Right arrow keys to select between digits. Note that the underlined digit is the one being changed. NOTE: Only 0 or 5 can be selected for the value to the right of the decimal point. If the count is using full cycles or an even number of half-cycles then the number to the right of the decimal point will be a 0. If the count is using an odd number of half-cycles then the number to the right of the decimal point will be a 5. IMPORTANT: If "00.0" counts are entered, (using as a timer, with no end-of-cycle) the lubrication cycle will be timed per the value selected for Alarm Units. If "00.0" counts are selected, fault detection is disabled. IMPORTANT: If a pressure switch is used in an injector system to signal a Lube Cycle Complete the cycle count should be 00.5. Press the ENTER key to save the Cycle Counts value and move to the Alarm Units field. Alarm Units Alarm Units Counts or Seconds or Minutes or Hours Use the Up and/or Down arrow keys to select the desired units. Press the ENTER key to save the Alarm Units value and move to the Alarm Time field. Revision (11-06) 6 Alemite Corporation

Centralized Lubrication System Controller Alarm Time Alarm Time XXXX [alarm units]

SER 387780

Use the Up and Down arrow keys to modify the digit to the desired value. Use the Left and Right arrow keys to select between digits. Note that the underlined digit is the one being changed. Press the ENTER key to save the Alarm Time value and move to the Pump Control field. Pump Control Pump Control Continuous or Pulsed Use the Up and/or Down arrow keys to select the desired pump control. Continuous pump control means that the pump will be energized for the entire lubrication cycle either time or number of counts. Continuous is used for electric motors and reciprocating pumps. The Pulsed pump control means that the pump will be energized for a configured time period and then be de-energized for three seconds. If the last pump ON cycle occurs before the selected divider valve cycle counts, the pump is held on until the number of divider valve cycle counts is reached or the alarm time is exceeded. Pulsed is used for single stroke pumps requiring the air or hydraulic supply to stop, allowing the piston to return to home position. If Continuous is selected: Press the ENTER key to save the selection and move to Power Up Mode. If "Pulsed" is selected: Press the ENTER key to save the selection and move to Pulsed On Time.

Pulsed On Time Pulsed On Time XX Seconds Use the Up and Down arrow keys to modify the digit to the desired value. Use the Left and Right arrow keys to select between digits. Note that the underlined digit is the one being changed. Press the ENTER key to save the Pulsed On Time value and move to the Pump Cycles field. NOTE: The pump "off" time is always 3 seconds. Pump Cycles Pump Cycles XX Cycles Use the Up and Down arrow keys to modify the digit to the desired value. Use the Left and Right arrow keys to select between digits. Note that the underlined digit is the one being changed. Press the ENTER key to save the Pump Cycles value and move to the Power Up Mode field.

Alemite Corporation

Revision (11-06)

SER 387780 Power Up Mode

Centralized Lubrication System Controller

The Power Up Mode determines the operation of the CLS 1000 upon each power up event. If Lube is selected then upon power up the CLS 1000 will immediately initiate a lubrication cycle. If Idle is selected then the CLS 1000 will wait for the configured time or cycle counts between lubrications before initiating the lubrication cycle. Power Up Mode Lube" or "Idle Use the Up arrow and/or Down arrow to select the desired power up operation. Press the ENTER key to save Power Up Mode value and move to the Fault Lock Out field. Fault Lock Out This field determines the operation of the CLS 1000 in case of a lubrication fault. If the Fault Lock Out is set to Yes then no more lubrication cycles will occur until the fault is cleared. If Fault Lock Out is set to No then the lubrication cycles will continue as configured but the fault condition and alarm will stay active. Fault Lock Out Yes" or "No Use the Up arrow and/or Down arrow to select the desired fault operation. Press the ENTER key to save the Fault Lock Out setting. With this field the configuration process has been completed. The controller will remain in the Set Up mode and cycle back through the configuration sequence. Pressing the MENU key will place the CLS 1000 into the Auto Run Mode. Please note that the configuration mode may be activated at anytime by pressing the MENU key.. Auto Run Mode During normal (no fault) operation in the Auto Run mode, the Lube Controller will be either in an Idle state, timing down to the next lubrication cycle, or in the Lube state with the pump activated to dispense lubricant. Idle Idle XXXX [off or idle units] The units show the time or machine counts before the next lubrication cycle. The Yellow (Lube) LED and Red (Fault) LED will be off.

Revision (11-06)

Alemite Corporation

Centralized Lubrication System Controller Lube (with 00.5 or more cycle counts) Lube XX.X counts (or strokes)

SER 387780

The units show the counts remaining in the current lubrication cycle. The Yellow LED will be on and the Red LED will be off. Lube (with 00.0 cycle counts) Lube Alarm off XXXX [alarm units] The units show the time remaining in the current lubrication cycle. The Yellow (Lube) LED will be on and the Red (Fault) LED will be off. Fault If a fault (alarm time or machine counts are reached before the cycle is complete) is detected, the Red (Fault) LED will come on and the Alarm Contact will be closed. The lubrication operation in progress is halted. If a Fault Lock Out has been selected during configuration, a fault will stop the programmed lubrication cycles. The LCD will show the fault and the Alarm Contact will be closed. Fault Enter to reset After investigation and correction of the fault conditions: Press the ENTER key to clear the fault and the lubrication cycles will resume. If a Fault Lock Out has not been selected during configuration, the controller continues to run lubrication cycles per the selected Set Up values operation. NOTE: The Red LED remains On and the Alarm Contact remains closed until the ENTER key is pressed to clear the fault.

Alemite Corporation

Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Manual Run Mode There is a Manual Run switch located on the upper side of the CLS 1000. If this Manual Run switch is pressed during Auto Run mode or during a Fault Lock Out it will cause the controller to run a single lubrication period per the values that have been set up. If there is a no fault condition or a fault with no Fault Lock Out, Auto Run will resume after one lubrication period. If there is a fault condition and a Fault Lock Out has occurred, the Fault Lock Out will continue after one lubrication period.

Manual Run Switch

Figure 2: CLS 1000 Lube Controller show location of the Manual Run Switch

There is also a provision to wire a remote Manual Run which will perform the same function as the local Manual Run switch. Please refer to Figures 3 and 11 for connector location and wiring examples.

Revision (11-06)

10

Alemite Corporation

Centralized Lubrication System Controller

SER 387780

Wiring Connections
The next section will describe some of the typical wiring connections used when installing the CLS 1000. Figure 3 shows the CLS 1000 connector terminal number and description. This information may also be seen on the CLS 1000 circuit board just below the connector. The wiring connector has a total of 21 terminals divided into three sections of 7 terminals. The terminal block may be removed by placing a flat screw driver in the slot at the back of the block and twisting. The blocks swing up and out. Each of the three terminal block sections has a specific purpose. The first, consisting of terminals 1 thru 7 is for power wiring connections. The second terminal block section, consisting of terminals 8 thru 14, is for the external pump and fault relay connections. The third terminal block section, consisting of terminals 15 thru 21, is for the contact and proximity sensor connections. The following sections discuss the typical wiring connections for each of the three terminal block sections. The Supply Power Wiring section will provide typical power wiring examples for 115 VAC (nominal), 230 VAC (nominal) and 30 VDC (nominal). The Pump Power and External Alarm Wiring section will provide typical examples using the same power source as supplies the CLS 1000 as well as using a separate power source. The section on input sensor wiring will proved typical wiring connections for Machine Cycle, Lube Cycle and Manual Run inputs. The final wiring section will provide wiring diagrams that show several typical complete wiring installation diagrams.

Alemite Corporation

11

Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Figure 3: Silkscreen of the CLS 1000 Connector Descriptions

Revision (11-06)

12

Alemite Corporation

Centralized Lubrication System Controller

SER 387780

Supply Power Wiring Examples

The following diagrams gives wiring examples for the first terminal block section, consisting of terminals 1 thru 7, which supply operating power to the CLS 1000. These connections provide power to the CLS 1000 electronics.

Figure 4: 85 135 VAC, 0.2 amp Power Connection

Figure 5: 170 265 VAC, 0.1 amp Power Connection

Alemite Corporation

13

Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Figure 6: 10-30 VDC, 0.4 amp Power Connection

Revision (11-06)

14

Alemite Corporation

Centralized Lubrication System Controller

SER 387780

Pump Power/Control and External Alarm Wiring Examples

The following wiring diagrams show examples of wiring control circuits for pumps and external alarm devices which are connected via the second terminal block section containing terminals 8 thru 14. The CLS 1000 does not supply power to external devices, such as the pump and alarming device, but controls the power fed to them via an internal 10 amp relay representations of which may be seen in the wiring diagrams. In typical applications, pump and external alarm power is supplied by the same source as powers the CLS 1000. This example is seen in the following diagrams. It should be noted that the pump and external alarm are not required to be powered from the same source as the one which supplies the CLS 1000. In this case, the connection to terminal pair 8,9 for the pump and terminal connections 11,12,13 for the external alarm will be connected to the device power supply (See Figure 10).

When selecting a fuse size the equipment sizes need to be taken into consideration. The fuse must be large enough to allow normal operation of all of the devices but small enough to provide protection. If the devices are being supplied from a power supply other that that supplying the CLS 1000 then those devices should be fused separately. If the pump to be used required more that the power (amperage) available then an interposing relay may be used to control a pump fed from a separate power source.

Figure 7: 85 135 VAC Power Connection with Pump Power and External Alarm Connections Alemite Corporation 15 Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Figure 8: 170 -265 VAC Power Connection with Pump Power and External Alarm Connections

Figure 9: 10 30 VDC Power Connection with Pump Power and External Alarm Connections Revision (11-06) 16 Alemite Corporation

Centralized Lubrication System Controller

SER 387780

Figure 10: 85 135 VAC Controller Power with DC Pump and Alarm Power

Alemite Corporation

17

Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Input Switch/Sensor Wiring Examples

This third section of wiring examples deals with the third terminal block section which consists of terminals 15 thru 21. This terminal block provides the connections for the contacts and proximity sensors that provide the control signals to the CLS 1000. The CLS 1000 utilizes external contacts and sensors to provide the necessary control signals. To make the required connections easier the CLS 1000 provides a DC voltage source adequate to power the dry contact and proximity sensor circuits. It should be noted that this DC voltage source is designed to power the sensor circuits and should not be utilized to supply power to any other circuits.

Manual Run Switch The Manual Run input allows the user to wire a remote switch which will perform the same function as the Manual Run Switch located on the top of the CLS 1000 (see page 10).

Figure 11: Remote Manual Run Switch Connection using a Momentary NO Dry Contact

Revision (11-06)

18

Alemite Corporation

Centralized Lubrication System Controller Machine Cycle Input

SER 387780

In typical applications there is some delay between lubrication cycles. This delay may be measured in time (seconds, minutes, hours) or by an event such as some number of machine cycles. If the delay is determined by a number of events occurring then the Machine Cycle Input is used. A machine cycle is defined as the changing of the position of the contact from its original position, to the secondary position and then back again. This input can utilize dry contacts or a proximity sensor. The following diagrams show typical connections schemes for various sensor types.

In the circuit in Figure 12, a machine cycle would be the changing of the dry contact from close, to open and then back to close. In this instance an NO or a NC dry contact could be used.

Figure 12: Machine Cycle Indicator Connection using a Dry Contact Input

Alemite Corporation

19

Revision (11-06)

SER 387780

Centralized Lubrication System Controller

The CLS 1000 is able to use proximity sensors in addition to dry contacts as input devices. These proximity switches are semiconductor devices that require power to function and change state based on whether metal is present or not. As seen in Figure 13, power is connected to the DC+ and DC- wires of the proximity sensor. The signal output of the sensor is connected to the Machine Cycle Count input of the CLS 1000.

Figure 13: Machine Cycle Indicator Connection using NPN Proximity Switch

Figure 14: Machine Cycle Indicator Connection using PNP Proximity Switch

Revision (11-06)

20

Alemite Corporation

Centralized Lubrication System Controller

SER 387780

Figure 15: Lube Cycle Indicator Connection using Dry Contact Switch

Figure 16: Lube Cycle Indicator Connection using NPN Proximity Switch

Alemite Corporation

21

Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Figure 17: Lube Cycle Indicator Connection using PNP Proximity Switch

Revision (11-06)

22

Alemite Corporation

Centralized Lubrication System Controller

SER 387780

General Wiring Examples

The following figures provide wiring examples for some of the more standard applications involving the CLS 1000.

Figure 18: 115 VAC Power, Pump, Machine Cycle Dry Contact, Lube Cycle Dry Contact, Low Level Dry Contact Switch NO Alemite Corporation 23 Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Figure 19: DC Power, Pump, Machine Cycle PNP Proximity Switch, Lube Cycle Dry Contact

Revision (11-06)

24

Alemite Corporation

Centralized Lubrication System Controller

SER 387780

Figure 20: 230 VAC Power, Machine Cycle Dry Contact, Lube Cycle Dry Contact, Low Level Sensor PNP NC

Alemite Corporation

25

Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Figure 21: 230 VAC Power, Machine Cycle Dry Contact, Lube Cycle Dry Contact, Low Level Sensor PNP NC Alternate Wiring, Same function as Figure 20

Revision (11-06)

26

Alemite Corporation

Centralized Lubrication System Controller

SER 387780

Figure 22: 115 VAC Power, Machine Cycle Dry Contact, Lube Cycle Dry Contact, High Pressure Dry Contact NO, Low Level Dry Contact NO

Alemite Corporation

27

Revision (11-06)

SER 387780

Centralized Lubrication System Controller

Revision (11-06)

28

Alemite Corporation