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1. autolube el Introduction Specifications General Precautions Keypad Layout Panel Description single Line System Fault Indication ge EL m pd Single Line System with pressure switch ol un Page 2 Page 3 Page 4 5 3 Page 6 Page 9 Page 19 Page 21 NS autolube electronic lubrication control unit manual setup procedures lt gt rm low Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com AUTOLUBE CONTOLLER MANUAL Lu 9 O Z ag tr a T z T T O oO He H frs autolube specifications The AUTOLUBE is a universal lubrication system controller capable of handling all common lubrication systems from the simplest run pause timer through progressive single and dual line systems Innovative algorithms also give new flexibility and greater control over traditional single line systems The practical layout gives clear indication of exactly what is happening at any time and the advantaged diagnostics will help to pinpoint any faults quickly Although highly flexible it remains simple to operate and program by using Ultra Flow s proprietary Lube Logic setup procedure By specifying what type of system is being used Lube Logic asks the user only relevant information in a clear step by2. The main centre for receiving and uploading of data needs to have a modem connected to their pc in order to send and receive data Each modem has its own identity and unique address Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com
3. what it was setup for to zero and then resume itspause cycle Note that the green LED will be steady on the pump section of the decal This is a indication that the pump is thereby not turning while it is in the VENT mode Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems single line system fault indications 2 2 E 5 ultra flow va Pt Jien am NOTE IN ORDER FOR A FAULT TO BE TOTALLY RESET THE UNIT MUST PERFORM COMPLETE CYCLE OF RUN AND PAUSE TO CANCEL AN EXISTING FAULT OUT OF MEMORY THE UNIT IS DESIGNED TO MEMORIZE THE TOTAL TIME OF ANY SPECIFIC FAULT THE ONLY WAY THE UNIT CAN FUNCTION CORRECTLY WITHOUT THE SAME FAULT OCCURRING IS FOR IT TO RUN 1 COMPLETE CYCLE Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems single line system wiring diagram with pressure switch lt 14 x AUTOLUBE CONTOLLER MANUAL Power Switch Power Supply Low Level Sensor External Warning Lamp Pressure Switch 9 O Z ag tr a T z T T O He H frs Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sa
4. bracket 555555 55555555555 SPECIFICATIONS VOLTAGE 10VDC TO 30VDC CURRENT DRAIN 150ma MAX no load 70ma nominal PUMP OUTPUT 7Arms MAX LAMP OUTPUT SWITCHING Solid state short circuit protected FUSE 8 Amp fast blow 20mm glass CONNECTION 14 way MOLEXMINIFIT JR COMMUNICATIONS RS232 Type DIMENSIONS 70mm X 145mm X 38mm including mounting bracket WEIGHT 300g PROTECTION IP54 TEMPERATURE RANGE 25C to 80C Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com 2 2 o lt A N AUTOLUBE CONTOLLER MANUAL 9 O Z ag tr a T z T T O He H frs general precautions The user manual is intended to familiarize the user with the autolube controller and its designated use The operating instructions contain important information on how to operate the autolube controller safely properly and efficiently Observing these instructions will help reduce confusion and actual damage to the autolube controller This manual must be read and applied by any person in charge of carrying out any form of setting up or work on the autolube controller Operational Precautions Includes the total understanding of the autolube specifications Never connect to any other voltage supply other than that specified in the manuals contained within The owner user must ensure at all t
5. pressure switch STEP 7 In the display the pressure switch timeout will now be displayed Press the up button to increase the duration of the timeout required Note on larger systems it may take longer to pressurize the complete system It is important that the system is tested to establish its timeout Add around 5096 more to the actual timeout for the system to operate effectively without timing out before it has reached its pressure status Press the ENTER button to accept your settings STEP 8 lt gt After you pressed the button Normally open will appear in the display This is an indication whether your pressure switch is normally open or normally closed Press the up button to choose between N O or N C Press the ENTER button to accept your choice 8 Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems single line system using a pressure switch STEP 9 lt gt ultra flow After pressing the ENTER button NO NO will appear in the display Note that the green LED on proxy2 is now illuminated Should you want to use a 2nd proxy then proceed by pushing the up button press enter to accept and proceed the setup as you would have for proxy1 Normally we use only 1pressure switch press the up button till NO appears in the dis
6. step manner and the operator need only concern himself with the particular system he is using The built in Real Time Clock allows the unit to log a history of operations and faults conditions Serial communications allows the operation history and setup to be modified altered via a PC By using the GSM option available all conditions can be monitored remotely using GSM cellular network and the unit can even be programmed to report any fault conditions to a remote PC located elsewhere in the country or in a different country FEATURES Runs progressive single line and dual line lubrication systems Real time clock logs date and time of faults 80 critical records RS232 serial port allows connection to PC Option to connect to GSM modem allowing remote monitoring via GSM networks Optional Dongle available for remote downloading of data without the need of a Laptop Timing intervals from 5 seconds to 24 hours Cycle Counting 10Vdcto 30Vdc operation Short circuit open circuit detection with audible warning External fault lamp drive Flash or steady output Low level reservoir monitoring Two sensor switch inputs Visual amp audible fault indication Non volatile memory Builtin blown fuse indicator 3 digit LED display indicates exact status of system Simple Lube Logic setup procedure Test mode allows testing of all the circuits connected to the Autolube for verifying Practical attractive housing with mounting
7. ultra flow hrs Y jm lt gt ultra flow 4 Ne n jm 19 STEP 11 After you have pressed the ENTER button NO will appear in the display Note that the green LED on reservoir will now be illuminated In this setup procedure you have the choice of selecting low level detection or not Should you not require low level detection then push the up button and select NO Press the ENTER button to accept In this example we are going to select the low level option Press the up button till YES appears in the display Press the ENTER button to accept your choice PLEASE NOTE THAT WHEN USING THE LOW LEVEL SENSOR A 10 SECOND DELAY ON STARTUP WILL TAKE PLACE THIS IS TO ENSURE THAT THE PADDLE ASSEMBLY IS IN THE RIGHT POSITION TO THE SENSOR AFTER 10 SECONDS OF RUNNING THE SENSOR WILL IMMEDIATELY ACTIVATE ON LOW LEVEL THE LOW LEVEL WARNING WILL BE DISPLAYED WHEN THE UNIT REACHES ITS PAUSE STATUS THE UNIT WILL NOT DISPLAY A LOW LEVEL WARNING WHILE IN RUN MODE STEP 12 After you have pressed the ENTER button N O Normally open will appear in the display This is an indication whether your sensor is normally open or normally closed Press the up button to choose between N O or N C Press the ENTER button to accept your choice Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra f
8. arno ultra flow com ultra f low Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com 2 2 9 lt x W 14 n l lt 14 W z Ww o autolube key pad layout E 2 lt m lt gt Lu lt Bracket LED Display AUTOLUBE CONTOLLER MANUAL P d aun Cycle Indicator Setup Indicator Second Indicator System Reset amp Pump Run Minute Indicator Enter Program Hour Indicator Select value down or silent buzzer Led Pump on Green amp Red when faulty Led Sensor 1 selected amp Red when Faulty PUMP Buzzer PROXY 1 2 RESERVOIR Fuse Led Sensor 2 selected amp Red when Faulty ww I Led Low Level selected amp Red when faulty 4 Blown Fuse Indicator Fuse Holder 8A __ Ignition Negative amp Positive RS 232 Connection Ignition to Standby Mode Sensor 1 Positive amp Negative Pump motor Connection Reservoir Sensor Connection External Lamp Sensor 2 Positive amp Negative 9 O z ag nd ah T E z T T O Oo He frs D Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sa
9. e Line Systems STEP 4 lt ultra flow As you press the ENTER button P Pause will now appear in the display By pressing the UP button you can change the time from any amount in seconds to minutes then to hours Note that the Led will change from seconds then to minutes and finally hours The amount in the display will indicate what the pause time will be Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems single line system using a pressure switch STEP 5 lt gt ultra flow Press the ENTER button to accept the pause time By pressing the ENTER button you have confirmed that you want to use a pause time of 4 hours as indicated hrs _ STEP 6 Note that when using Single line Systems the RUN time will default to that of cycles In the display it would either show 99 cycles or what ever cycles was setup before In this example we are going to setup 1 cycle The unit will only look for 1 signal from the pressure switch before going into VENT time Press the ENTER button to accept and proceed to the next setup procedure ultra flow N jres P2 ien ues Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems single line system using a
10. el 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems in the display This indicates that you are now in the test mode of your setup procedure By pressing the up button you will note that your pump will now start turning Should the pump turn in the wrong direction itis now possible to correct by changing the polarity of your wiring It is possible to check all other sensors as well by energizing them manually and watching if the green LED illuminates in that process If the LED does not illuminate then there is a problem either with the wiring or setup procedure i a lt 2 single line system using a pressure switch m lt gt 2 m a E 2 2 15 gt m After pressing the ENTER button TST will appear lt If all is correct you may turn of the power supply to the autolube controller PUMP 1 PLEASE NOTE THAT TST MUST APPEAR IN THE DISPLAY BEFORE SWITCHING THE POWER RESERVOIR Fuse TO THE UNIT SHOULD YOU SUITCH OFF POWER TO THE UNIT WHILE IT 15 I ANY PART OF THE PROGRAMMING THE SUSTER WILL NOT SAVE YOUR CHANGES TST MUST APPEAR IN THE DISPLAY IN ORDER FOR THE CHANGES TO ACCEPTED 9 O ag tr a T z T T O oO He H x Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 e
11. imes that installation or inspections are executed by authorized and qualified personnel who have thoroughly read the operating instruction manual Any setting up or work on the autolube controller must be done while the machine is off The machine must be in such a position that it will not cause harm to any person should the machine be switched on for the setting up ofthe autolube controller In the event that the machine needs to be on for the setting up of the autolube controller it must be on condition that the operatoror personnel working on the machine are advised Never switch the machine on without the prior knowledge of the operator owner or somebody that has full knowledge ofthe machines operation Warnings Never weld on a machine while the main switch of the machine is on Insure that the machines main switch is off and correctly tagged Welding on a machine can cause serious damage to the autolube controller Do notalter or modify any part ofthe autolube controller Insure that the autolube controller in mounted in an suitable area Do not mountthe autolube controller near excessive heat area s Always use the right specified fuse rating for the autolube controller Never exceed the voltage rating of the autolube controller Never expose the autolube controller to direct sunlight Never expose the autolube controller to water or other substances MANUFACTURER Ultra Flow Lubrication Systems c c Email technical inquiries
12. les ultra flow com url www ultra flow com optional equipment autolube controller remote data shuttle AUTOLUBE DATA SHUTTLE lt gt ra f low ultra flow CHANNEL UPLOAD ADS 2 Data Unit Oresa Pa Price autolube controller has the capacity to store all critical faults up to 80 records The Data Shuttle is a device that can retrieve this data without the use of a laptop PC The data shuttle can retrieve information from up to 100 different controllers This information can be then downloaded from the Data Shuttle to your desktop PC to the autolube program whereby all the relevant faults can be scrutinized The Data Shuttle has its own battery power and all information downloaded from the autolube controllers will be safely stored without the risk of loss Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com optional equipment autolube controller gsm modem gt lt gt ultra flow ultra flow BLS SETUP 99 a The autolube controller can also communicate together with a GSM modem This is the ultimate tool for downloading data from the autolube and more importantly to upload information and settings to the controller without having to send a technician to site The gsm modem needs to be installed together with the autolube controller
13. les ultra flow com url www ultra flow com panel description SLS Single Line Systems PLS Progressive Line Systems DLS Dual Line Systems N O Normally Open Sensors N C Normally Closed Sensors L S External Lamp Steady Continues supply L F External lamp Flashing Pulsed Supply Non Fatal Error Pump Continues on Low Level Fault Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com panel description R Run Time in Cycles P Pause Time in Sec Min or Hrs F Fault Time in Sec Min or Hrs U Vent Time in Sec Min or Hrs RCC Run Cycle Counter YES Yes for accepting program changes TST Test Mode for Checking Installed Devices T Time out or Dwell Time for Sensors Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com panel description gt ES al D a l lt Fatal Error Pumps Stops on Low Level Fault AUTOLUBE CONTOLLER MANUAL NO Do Not Select Selection R Run Time in Secs Mins and Hours Standby Mode zZ nd O 84 oO Z lt T He O e 0 Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems single line system u
14. low com url www ultra flow com manual setup for single line systems single line system using a pressure switch STEP 13 After you have pressed the ENTER button either FE Fatal Error or NFE Non Fatal Error will appear in the display The option of using FE Fatal Error is for the pump to stop on a low level warning This is mostly used on pumps with reservoir capacities of 1L to 10L It is preferred to stop the pump at low level in order to maintain a layer of grease above the pump element area This would help by not allowing an air pocket to form around the pump element when filling up the reservoir In the case of NFE Non Fatal Error it is mostly used on larger pump reservoirs whereby the distance of the pump tube to the bottom of the reservoir is substantial Select your choice and press the ENTER button STEP 14 lt gt After pressing the ENTER button L F Lamp Flashing ultra flow will appear in the display This option is for an external warning lamp to be fitted Normally if you have any sort of monitoring installed then this function will be used By pressing the up button the status will change from L F Lamp flashing to L S Lamp static L F is a pulsed output supply and L S is a constant output supply Press the ENTER button to move onto the next part of the programming B P2 Pt ren fae Contact us T
15. mail sales ultra flow com url www ultra flow com manual setup for single line systems single line system using a pressure switch gt ultra flow DE RUN CYCLE MODE After the power has been terminated on the unit then switched on again the unit will proceed in its run mode All devices teen selected will now be displayed Note that after each cycle received the amount will decrease by 1 until all cycles have been reached and the unit will proceed to its pause time Running System Pump run When the controller is switched on the run cycle counter will appear in the display as it was setup for The counter will appear from the actual counts set and count down to zero The green LED will indicate that you are in run cycle counter The green LED on the pump function will be flashing indicating that the pump is now turning or pumping Running System Pump pause When the controller has reached the required cycle counts it will go into its pause time that it was setup for The pause time will count down from what it was setup for to zero and then resume its cycle count Note that the green LED will be steady on the pump section of the decal This is a indication that the pump is thereby not turning while it is in the pause mode Running System Vent time When the controller has reached the required cycle counts it will go into its VENT time that it was setup for The VENT time will count down from
16. play Press the ENTER button to accept your choice STEP 10 VENT TIME gt ultra flow After you have pressed the ENTER button U VENT will appear in the display This is an indication of what the time in seconds minutes of the actual time it takes for the system to VENT before proceeding into its next cycle or pause time It is possible now to setup SLS with multiple cycles For example if you setup your cycles to 2 then the unit will operate for 1 cycle then go into a VENT time of 1 minute as indicated in the display After that minute has elapsed then the pump would turn back on and proceed with the next cycle As soon as the second cycle has been reached then the VENT time U would appear in the display and time itself out for the time that it has been setup for After it has completed the 2 cycles and its VENT time then only will the unit proceed into its pause time For this example we are only using 1 cycle and therefor only require a short VENT time as no further cycles are required before reaching its pause sequence E Press the ENTER button to accept the VENT time and le jres P2 Pt proceed to the next part of the setup procedure Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems single line system using a pressure switch lt
17. sing pressure switch DM ultra flow Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems single line system using a pressure switch STEP 1 lt gt ultra flow To enter the setup mode of the autolube controller press the ENTER button hold and keep depressed while switching on the ignition switch or any other power source to the controller Let go the ENTER button and the red LED Setup should now be illuminated The green LED on the description PUMP will be flashing PLS Progressive Line Systems should also appear in the display STEP 2 To select what type of system you require press the RUN PAUSE up button and this will change the type of system required By pressing the UP button the next system displayed will be SLS Single Line Systems the next system displayed after that would be DLS Dual Line Systems Continue to press the UP button till SLS is displayed This procedure will enter into the Single Line Mode ultra flow Contact us Tel 27 21 551 7496 Fax 27 21 551 7495 email sales ultra flow com url www ultra flow com manual setup for single line systems single line system using a pressure switch STEP 3 lt gt ultra flow Press the ENTER button to accepts SLS By pressing the ENTER button you have confirmed that you want to use Singl
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