Graco Trabon Lc 1000 Users Manual 14540
LC-1000 to the manual b1809739-3d26-4b44-ab4b-322102a6a3b0
2015-01-25
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LC-1000 Lube System Controller The Trabon microprocessor based LC-1000 Controller is a multi-use solid state controller that is dedicated to the operation and monitoring of intermittent operating series and parallel centralized lubrication systems equipped with a cycle or pressure switch for cycle completion feed back. The LC-1000 monitors and schedules lubrication intervals in either time or stroke/cycle basis in values ranging from 1 to 9999. Pump may be self cycling or single cycle type requiring a pulsed output. Four units are available for 12 VDC, 24 VDC, 115 VAC, or 230 VAC operation. The LC-1000 is easy to program in the field using four mini push-buttons. The programming requires no special knowledge or training of computer language. During power down or outage, all data is saved in EEPROM (Electrically Erasable Programming Read Only Memory). As power is restored, counting and pump status are restored to values prior to the loss of power. SPECIFICATIONS Display Supertwist LCD Annotated 4 Digit 4 LED’s: PWR (GN), LUBE (YW), FAULT (RD), CYCLE (YW) Stroke Input Maximum Input Rate: 10 hz (600 CPM) Nominal 12 Volts for 12 VDC Version Nominal 24 Volts for 24 VDC, 115 VAC, 230 VAC Versions Power Supply 115 VAC + 10%, 50/60 Hz, 1 ph 230 VAC + 10%, 50/60 Hz, 1 ph 12 VDC + 10% 24 VDC + 10% Selectable for either Source or Sink Solid State Proximity Switch or Dry Contact 10 mA Max. Output Loading Main Pump Load: ..........12 VDC – 230 VAC, 50/60 Hz 10 Amp Relay Output (External Fused by User) Programming Selection Output ON: ...................... 1 to 9999 Seconds, Minutes, Hours, Counts Output OFF:..................... 1 to 9999 Seconds, Minutes, Hours, Counts Cycle Counter: .............................Half Counts (0 to 99) Pump: ....................................... Steady State or Pulsed Pulse Off Time (Prime) – 3 Seconds Fixed Pulse On Programmable - 0 to 99 Seconds (Pre-Lube function is not available) Fault Output Signal: ........12 VDC – 230 VAC, 50/60 Hz 1 Amp Resistive Max. (N.O.) Dry Isolated Contact (External Fused by User) Temperature Range Do Not Locate unit in Direct Sunlight Operating:: -20OC to 50OC (-4OF to 122OF) Storage: -25OC to 60OC (-13OF to 140OF) Enclosure Plastic with Clear Cover, NEMA 4X, IP 66 Other Inputs Cycle Switch: ........12 Volts, Dry Contact, 2.5 mA Max. Counts Half Cycles Program Entry 4 Mini Push Buttons – Program, Increase, Shift, Enter EEPROM Electrically Erasable Programming Read Only Memory LC-1000 Lube System Controller 14540 WIRING INFORMATION Option for units built after February 1, 1999 that are programmed in time mode. INPUT VOLTAGE 3 4 + - + PUMP 5 6 7 8 9 FAULT 2 FAULT 1 PUMP DRY CONTACT (SEE NOTE 1) 10 11 12 12 VDC 13 14 15 16 18 17 19 NEU HOT FIG 1 DO NOT USE INPUT OUTPUT JUMPER INSTALLED MANUAL RUN DO NOT USE OPTIONAL LOW-LEVEL SWITCH AND/OR HIGH PRESSURE SWITCH. BOTH MUST BE OPEN DURING NORMAL SYSTEM OPERATION. CYCLE SWITCH (SEE NOTE 2) CLOSURE OF SWITCH CONTACTS CAUSES LC-1000 TO INDICATE A FAULT CONDITION. BUT PUMP WILL CONTINUE TO OPERATE. Note 1: 12 VDC with 12 VDC Input Voltage 24 VDC with 24 VDC, 115 VAC and 230 VAC Input Voltage Note 2: Piston Distributor or Injector System will use a Pressure Switch. WIRING INFORMATION All units programmed in machine count mode, or any units built prior to Februay 1, 1999. Option for units built after February 1, 1999 that are programmed in time mode. INPUT VOLTAGE 1 2 3 4 + - + - PUMP PUMP DRY CONTACT 5 6 7 8 9 (SEE NOTE 1) 10 11 12 12 VDC 13 14 15 16 17 18 19 OUTPUT SW SENSE SW IN SW DO NOT USE FAULT INPUT + FAULT NEU HOT FIG 2 MACHINE COUNT (SEE FIG 3 THRU 5) MANUAL RUN DO NOT USE OPTIONAL LOW-LEVEL SWITCH AND/OR HIGH PRESSURE SWITCH. BOTH MUST BE OPEN DURING NORMAL SYSTEM OPERATION. CYCLE SWITCH (SEE NOTE 2) CLOSURE OF SWITCH CONTACTS CAUSES LC-1000 TO INDICATE A FAULT CONDITION. ON EXPIRATION OF THE NEXT ON (MONITOR) PERIOD. SUSPENDING OPERATION OF THE PUMP. Figure 3, 4 and 5 refer to machine count input only. FIG 4 FIG 3 10 10 11 11 12 12 13 DRY CONTACT SWITCH 13 SOURCE SWITCH 2 OR 3 WIRE TYPE FIG 5 10 11 12 13 SINK SWITCH 2 OR 3 WIRE TYPE Page 2 LC-1000 Lube System Controller 14540 DIMENSIONS mm / (Inches) 76.2 (3.00) 127.0 (5.00) 114.3 (4.50) LUBE SYSTEM CONTROLLER 127.0 (5.00) 114.3 (4.50) TIME COUNTS REMAINING POWER LUBE FAULT CYCLE PRGM S X ENTER MANUAL RUN MODEL LC-1000 4.8 (.19) MANUAL RUN BUTTON ORDERING INFORMATION PUSH BUTTONS: There are four mini push buttons; LC-1000 Controller VOLTAGE PART NUMBER 12 VDC 163-400-050 24 VDC 163-400-051 115 VAC, 50/60 Hz 163-400-052 230 VAC 50/60 Hz 163-400-053 Replacement Board ON (Monitor Time) OFF (Pause Time) CYCLE (Switch Transitions) PUMP (Pulsed On Time) S - Increase digit VOLTAGE PART NUMBER 12 VDC 572-144-644 24 VDC 572-144-645 115 VAC, 50/60 Hz 572-144-646 230 VAC 50/60 Hz 572-144-647 PROGRAMMING INSTRUCTIONS The LC-1000 Controller has icons in the display to indicate if the unit is in a lube ON cycle or OFF cycle and to show the timing mode. They are also used to indicate which counter is being adjusted when programming new parameters. The LCD four digit display is used to show the remaining time left in either an ON or OFF cycle, as indicated by the icons. Timing can be done in seconds, minutes, hours or counts. A flashing LCD character indicates that the timer is in the Programming mode. Page 3 PRGM - Initiate Program mode, or alternate between settings for: X - Next digit select ENTER - Enter (save) new setting and advance to next program step. LC-1000 Lube System Controller OPERATION When power is applied, the green “POWER LED”lights and the LC-1000 counts down alternately from the programmed “OFF/ON” Times/Counts to zero. In the “ON” (Monitor) mode, the ” PUMP LED” lights. The pump is activated and both the “ON and “RUN” icons are displayed. If the programmed number of cycle switch transitions (1/2 cycles) are received before expiration of the “ON” (Monitor) period, the PUMP OUTPUT, “PUMP” LED, “ON” and “RUN” icons turn off and the “OFF” icon will display. If the programmed number of cycle switch transitions (1/2 cycles) are not received before expiration of the “ON” (Monitor) period, a “Fault” will be registered. This suspends pump operation, turns off the ” PUMP” LED, the “ON and “RUN” icons, turns on the red “FAULT” LED and closes the fault output contacts. If a pulsed output to the pump is required, a “PUMP ON” time may be programmed from 0 to 99 seconds. Setting this value to zero will provide a steady state output. “PUMP OFF” is fixed at 3 seconds. The “RUN” icon will display anytime the pump output is energized. During pulsed pump operation, the “RUN” icon will flash on and off in sequence with the pump. During continuous running, the “RUN” icon will not flash. The Controller is programmed to retain the Time/Count in memory when power is turned off. This feature prevents excessive lubrication in start/stop applications and retains information for cycle to be completed when power is restored. CHANGING SETTINGS From the Timer display mode, pressing the “PRGM” button will allow you to review or change between the set “ON” (Monitor), “OFF”, “CYCLE, “PUMP” (Pulsed On Time) and “DISPLAY” modes. When in the programming mode, the icons/digits will blink. When in the display mode, the icons/digits do not blink. 1. To set a new “ON” (Monitor) Time/Count, press the “PRGM” key until the “ON” icon blinks. The current “ON” (Monitor) Time/Count will be displayed. a) Press the “ENTER” key. The “ON” (Monitor) Time/Count digit will blink. b) Change the value using the S key and X key. c) Press the “ENTER” key to accept the new value. The “SEC/MIN/HR/CNT” icon will blink d) Press “ENTER” to accept the time base or the S key to scroll through the timing choices. 14540 e) Press “ENTER” to complete the process (Note: Monitor period is normally set 2 times the actual time required for the pump to satisfy the system cycle requirements). 2. The “OFF” icon will now be blinking. a) Repeat above process until all “OFF” options have been programmed. b) Press “ENTER” to accept the new values. 3. The “CYCLE” icon will now be blinking a) Press “ENTER” and the cycle value (1/2 cycles) will blink. b) Using the S and X keys set the cycle value as follows: Series Progressive: ...............02 (1 divider cycle), 04 (2 divider cycles), 06 (3 divider cycles), etc. Dual Line: ................. 01 (half cycle) 02 (full cycle) Piston Distributor or Injector: ......................... 01 c) Press “ENTER” to register the new value. 4. The “PUMP” icon will now blink. a) Press “ENTER” again and the pump pulsed “ON” time will blink. b) Using the S key and X key, set the value (seconds) as follows: Self-Cycling Pump (Motor Driven, or Reciprocating Barrel): ...... 00 Single Shot Pump (Piston Distributor, or Injector): ................... 00 Single Shot Pump (Recycle for Series Progressive): ........ 03 to 10 c) Press "ENTER" to accept the new values. NOTE: In the Recycle mode, PUMP “OFF” time is fixed at 3 seconds. Press “ENTER” to register the new value and return to the “DISPLAY” mode. NOTE: Scrolling through the modes using the“PRGM” key only will allow the review of the current settings without changing any of the values or timing. It is recommended that programming not be attempted while a lube cycle is in process. After making any change in settings, activate a manual run to initiate the change. NOTE: Programming examples for specific types of systems are shown on pages 5, 6 and 7. MANUAL RUN / RESET A manual-run lubrication cycle may be initiated by pressing the manual run button, located on the left underside of the unit, OR by shorting terminals 14 and 15 together, such as with a remote push-button momentary switch. Manual run may also be initiated by pressing S and "ENTER" keys together. Manul run is also used to reset the controlelr and to clear faults. Page 4 LC-1000 Lube System Controller 14540 Sample LC-1000 Program for Series Progressive, 31 Point Series Progressive System DESCRIPTION ■ ■ ■ ■ ■ ■ ■ ■ ■ System Lube Volume: 6.0 cu in (99 cc) per hour AL-50 Pump Used: .24 cu in per stroke (3.9 cc) Master Divider Volume per Cycle: .15 cu in (2.4 cc) Cycle Interval 15 Minute (1/4 hour) Used Volume per Lube Cycle: 6.0 cu in/4 = 1.5 cu in/15 min. Master Divider Cycles/Lube Cycle: 1.5 cu in/.15 cu in = 10 cycles Cycle Switch Transitions (2 transitions/cycle) x 10 = 20 Pump Strokes per Lube Cycle: 1.5 cu in/.24 cu in = 6.3 (use 7) Monitor Time: 7 Strokes x 6 seconds/stroke (3 second "ON", 3 second "OFF") = 42 second x 2 (safety factor) = 84 seconds. PUMP AND RESERVOIR MASTER DIVIDER VALVE CYCLE SWITCH LARGE BEARINGS SECONDARY DIVIDER VALVES PROGRAMMING 1. Initiate Programming Mode a) Press “PRGM” Key – “ON” Icon blinks 2. “ON” (Monitor Period) a) Press “ENTER” Key – ON TIME/COUNT blinks b) Use S Key and X Key to set Monitor (“ON”) Time to 0084 c) Press “ENTER” Key to accept value; “SEC/MIN/HR/CNT” blinks d) Use S Key to scroll through choices; select ” SEC” e) Press “ENTER” Key to accept choice; “OFF” Icon blinks 3. “OFF” (Pause Time) a) Press “ENTER” Key – OFF TIME/COUNTblinks b) Use S Key and X Key to set “OFF TIME” to 0015 c) Press “ENTER" Key to accept value; "SEC/MIN/HR/CNT" blinks d) Use S Key to scroll through choices; select “MIN” e) Press “ENTER” Key to accept choice; “CYCLE” Icon blinks Page 5 4. “CYCLE” (Cycle Switch Transitions) a) Press “ENTER” Key; CYCLE (switch transitions) blinks b) Use S Key and X Key to select 20 (20 cycle switch transitions = 10 Divider cycles) c) Press “ENTER” Key to accept value; ”PUMP” Icon blinks 5. “PUMP ON” (Pump Duty-Pulsed/Non-Pulsed) a) Press “ENTER” Key – “PUMP” (pulsed on time) blinks b) Use S Key and X Key to set ” ON TIME” TO 03 (3 sec pulsed output) c) Press “ENTER” Key to accept value; LCD returns to “DISPLAY” mode Programming is now complete. To verify lube sequence, initiate a manual lube cycle by pressing “MANUAL RUN” button. NOTE: If an electric motor driven pump or self cycling barrel pump is used, enter “00” in Step 5b for non-pulsed output. LC-1000 Lube System Controller 14540 Sample LC-1000 Program for Piston Distributor or Injector Systems 31 Point Piston Distributor System DESCRIPTION ■ ■ ■ ■ ■ ■ ■ ■ System Lube Volume: 99 cc (6.0 cu in) per hour EO-3 Motor Driven Pump: 140 cc/min (8.5 cu in) Total Piston Distributor Displacement: 4.62 cc/cycle (.28 cu in) Cycle Interval: 99 cc / 4.62 cc = 21.4 cycles/hr 60 min/21.4 cyc = 2.8 min (168 sec) per cycle Cycle Switch (Pressure Switch) Transitions: (1 transition/cycle) x 1 = 1 Pump Run Time: 4.62cc/140cc = .033min (1.98 second) Monitor Time: 1.98 sec x 2 (safety factor) = 3.96 seconds LUBRICATION POINTS PISTON DISTRIBUTORS PRESSURE SWITCH VENT VALVE VENT LINE PUMP AND RESERVOIR Note: Due to the very short calculated pump run time, use a 20 second monitor time. PROGRAMMING 1. Initiate Programming Mode a) Press “PRGM” Key – “ON” Icon blinks 2. “ON” (Monitor Period) a) Press “ENTER” Key – ON TIME/COUNT blinks b) Use S Key and X Key to set Monitor (“ON”) Time to 0020 c) Press “ENTER” Key to accept value; “SEC/MIN/HR/CNT” blinks d) Use S Key to scroll through choices; select ” SEC” e) Press “ENTER” Key to accept choice; “OFF” Icon blinks 3. “OFF” (Pause Time) a) Press “ENTER” Key – OFF TIME/COUNT blinks b) Use S Key and X Key to set “OFF TIME” to 0168 c) Press “ENTER” Key to accept value; "SEC/MIN/HR/CNT" blinks d) Use S Key to scroll through choices; select “SEC” e) Press “ENTER” Key to accept choice; “CYCLE” Icon blinks 4. “CYCLE” (Pressure Switch Transitions) a) Press “ENTER” Key; CYCLE blinks b) Use S Key and X Key to select 01 (1 pressure switch transition = 1 system cycle) c) Press “ENTER” Key to accept value; ”PUMP” Icon blinks 5. “PUMP ON” (Pump Duty-Pulsed/Non-Pulsed) a) Press “ENTER” Key; "PUMP" (pulsed on time) blinks b) Use S Key and X Key to set ”ON TIME” TO 00 (non-pulsed output) c) Press “ENTER” Key to accept value; LCD returns to “DISPLAY” mode Programming is now complete. To verify lube sequence, initiate a manual lube cycle by pressing “Manual Run” button. Page 6 LC-1000 Lube System Controller 14540 Sample LC-1000 Program for Bi-Flo (Dual Line) Systems 31 Point Bi-Flo (Dual Line) System DESCRIPTION ■ ■ ■ ■ ■ ■ ■ System Lube Volume: 6.0 cu in (99 cc) per hour Bi-Flo Motor Driven Pump Used: 8.6 cu in (141 cc) per minute. Note 1: Requires a Motor Starter Note 2: Requires a hydraulic reverser with cycle switch. Cycle Interval 15 Minute (1/4 hour) Used Volume per Lube Cycle: 6.0 cu in/4 = 1.5 cu in/15 minute. Cycle Switch Transitions (2 transitions/cycle) x1=2 Pump Run Time per Lube Cycle: 1.5 cu in/ 8.6 cu in = .17 min (10.4 second) Monitor Time: 10.4 sec x 2 (safety factor) = 20.8 second (use 21 second). PUMP AND LUBRICATION POINTS RESERVOIR VENT LINE INDICATORS REVERSER CYCLE SWITCH BI-FLO VALVES PROGRAMMING 1. Initiate Programming Mode a) Press “PRGM” Key – “ON” Icon blinks 4. “CYCLE” (Cycle Switch Transitions) a) Press “ENTER” Key; CYCLE (switch transitions) blinks b) Use S Key and X Key to select 02 (02 cycle switch transitions = 1 System cycle) c) Press “ENTER” Key to accept value; ”PUMP” Icon blinks 2. “ON” (Monitor Period) a) Press “ENTER” Key – ON TIME/COUNT blinks b) Use S Key and X Key to set Monitor (“ON”) Time to 0021 c) Press “ENTER” Key to accept value; “SEC/MIN/HR/CNT” blinks d) e) 5. “PUMP ON” (Pump Duty-Pulsed/Non-Pulsed) a) Use S Key to scroll through choices; select ” SEC” Press “ENTER” Key "PUMP" (pulsed on time) blinks b) Press “ENTER” Key to accept choice; “OFF” Icon blinks Use S Key and X Key to set ”ON TIME” TO 00 (Non- pulsed output) c) Press “ENTER” Key to accept value; LCD returns to “DISPLAY” mode 3. “OFF” (Pause Time) a) Press “ENTER” Key – OFF TIME/COUNT blinks b) Use S Key and X Key to set “OFF TIME” to 0015 c) Press “ENTER” Key to accept value; "SEC/MIN/HR/CNT" blinks d) Use S Key to scroll through choices; select “MIN” e) Press “ENTER” Key to accept choice; “CYCLE” Icon blinks Page 7 Programming is now complete. To verify lube sequence, initiate a manual lube cycle by pressing “MANUAL RUN” button. NOTE 1: If half cycle Bi-Flo (Dual Line) operation is desired, select 01 (one switch transition) in step 4b. NOTE 2: If a single cycle pump is used in conjunction with a Bi-Flo Reverser, enter “03” in Step 5b for pulsed pump output (3 second "ON", 3 second "OFF"). Your Program Record Company: _____________________________________ By: _______________________ Machine Identification: __________________ Date: _____________________ System Type: Bi-Flo ___ Piston Distributor ___ Series ___ Other: _________________ On (Monitor) Value: Time/Count _____ Seconds ___ Minutes ____Hours ___ Counts _____ Off Value: Time/Count _______ Seconds ______ Minutes ______ Hours ____ Counts ______ Cycle Value (Switch Transitions): ______________________ Pump On (Pulsed/Non Pulsed): ____________ (00 is NonPulsed) TROUBLESHOOTING Symptom Blank Display, No LEDs No Display or Black Display, but System Operates Program Will Not Run Can’t Change Program Fault Light On Failure to Indicate a Fault Cause Remedy No Power Check Wiring & Fuse-Repair as Required Bad Circuit Board Replace Circuit Board Temperature too High or too Low Move Controller to Location that is within Temperature Limits Bad Display Replace Circuit Board Programming Error or Bad Circuit Review Instructions & Examples-Reprogram/ Board Replace Circuit Board as Required In Programming Mode Exit by Pressing PRGM Programming Error or Bad Circuit Board Review Instructions & Examples-Reprogram/ Replace Circuit Board as Required Power Off Before Programming Completed Complete the Programming Process Before Removing Power No Cycle Input Check Cycle Switch & Wiring-Repair as Required Level Sw. or HP Sw. Closed (If Used) Check Reservoir Level and Operating PressureRefill/Repair as Required System Blockage Correct Blockage (see Bul 30101) No Pump Flow or Low Flow Check Reservoir Level & Pump Output-Refill/Repair as Required Main Line Leaks Check & Repair as Required Plugged Filter/Strainer Clean or Repair as Required Monitor Time too Short Increase Monitor Time Cycle Count Set to 00 Set Cycle Count to Desired Number of Half-Cycles. Programmed Machine Count Mode, and Wire According to Fig. 1 Program On and Off in Time Mode, or Wire per Fig. 2. All written and visual data contained in this document are based on the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice Call today for product information or to request a demonstration. 1.800.USA.LUBE (1-800-872-5823) or visit us at www.lubriquip.graco.com. ®2006 Graco Inc. Bulletin 14540, July 2000. Printed in U.S.A. All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
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