6&12 GAL. SINGLE LINE UNITCENTRAL SYSTEMS

TABLE OF CONTENTS

INTRODUCTION PAGE 1 SECTION I—DESCRIPTION PAGE 2 Automatic Conveyor Lubricator SECTION II—SPECIFICATIONS PAGE 3 SECTION III—SEQUENCE OF OPERATIONS PAGE 4 SECTION IV—LUBRICATOR SETTINGS PAGE 4 Lubrication Programming SECTION V—LUBRICATOR INDICATORS PAGE 5 External Lights on Centralized Pumping Station Light Emitting DIODE on Circuit Board Panel SECTION VI—INSTALLATION PAGE 6 Selecting the Lubricator’s Location Installation of SLU-units Monitoring of the Lubricator PAGE 7 Connecting the Electrical Power PAGE 8 Lubricator—Start-Up Procedure and Settings System Maintenance PAGE 9 SECTION VII—LIMITED WARRANTY PAGE 10

INTRODUCTION

CONGRATULATIONS! You have purchased the most technically advanced and reliable lubrication system on the market today. It will provide you with years of dependable lubrication if properly installed and serviced. This manual provides instructions of the installation and maintenance of your Castrol LubeCon conveyor lubrication system. Read carefully the correct section pertaining to the adjustment that you wish to make. Castrol LubeCon lubricators are equipped with circuit boards which have multiple logic functions programmed into the logic circuitry so that different type conveyor lubricators could use the same circuit board, thereby reducing your stock of replacement parts. Your particular application may not require the use of all the available features so the setting for the unused features may be omitted. Some lubrication systems are specially designed to customer specifications, so additional pages may be inserted into this manual for clarity. CONFIDENTIAL This manual provides confidential information concerning the operation of the Castrol LubeCon Lubrication system. It is provided to help valued Castrol customers—not competitors.

1

SECTION I Description Automatic Conveyor Lubricator The Castrol LubeCon Automatic Conveyor Lubricator provides precise and dependable placement of lubricant to the conveyor’s chain pins and/or open bearings. The lubrication system consists of a lubricator controller, solenoid valves, detection switches and dispensing tubes, and a pumping unit that provides the lubricant from the reservoir to the lubricator. Also included in the installation instructions is a section on installing the centralized pumping station and its adjustments, if applicable. Parts listings and instructions are included for each specific unit.

2

SECTION II Specifications Weight: 6 Gal. - 70lbs. 12 Gal. - 85lbs (Less track section if pre-mounted)

Overall dimensions: See Section VI Circuitry: Solid State Air requirements: None Max amp draw of 24 VDC supply: 1 amp Reservoir capacity: 6 or 12 gallons (depending on model) Operation temperature: 60—120° F Lubricant viscosity range: Low viscosity system: Maximum 10 cSt @ 40° C Pressure range: 0—45 psi Lubricant shot volume: Adjustable Fill: Filter—Vent cap Filter: Pumping Unit—Inlet Strainer Maximum distance from SLU-UNIT to lubricator valve: 75 feet Maximum distance from photo Switch: Variable depending on project can be custom fitted Supply voltage: 115 VAC, 15 amp dedicated line Reservoir supply tubing: 1/4” diameter nylon Number of Output Channels: 3

3

SECTION III Sequence of Operations The lubricator is designed so that it may be programmed to lubricate per your settings. Once the settings are established, all functions become automatic and require very little attention. In general, the lubricator will count individual chain links, trolley bearings, or rollers to determine a complete cycle of the conveyor. The lubricator will remain off until the number of “off cycles” (or non-lubrication cycles) has been obtained and then lubricate for one complete conveyor cycle. It will then go back and start over on the preset number of “off cycles”. When a dispenser is in an “off cycle”, the dispenser will not be operating, however, the detection switch will still be operating. An LED indicator on the detection switch will signify that the switch is operating properly. When a dispenser’s lubrication cycle begins, the lubricant pump unit will start and supply lubricant to the dispenser. Throughout the lubrication cycle the pumping unit will continue to supply lubricant to the lubricator’s dispensers. Each time a detection switch is activated, the dispenser will dispense lubricant onto the desired points. After the lubrication cycle is completed, the dispenser will dispense lubricant onto the desired points. After the lubrication cycle is completed, the dispenser will stop dispensing lubricant and the pumping unit will automatically shut off until its next request for lubricant. The pumping unit also has an automatic “shut-off” should the lubricant tank become empty or should the conveyor stop for over three minutes during the lubrication cycle. When the conveyor restarts, the lubrication cycle will also resume where it had left off. The pumping unit should be wired to a power source that always remains “on”. Frequent power interruptions do not permit the lubricator to function properly in an automatic position. SECTION IV Lubricator Settings (SLU Controller) The Castrol LubeCon lubrication system is controlled by solid state circuitry that provides the user with the ability to insert the desired lubrication settings and to change settings whenever required, while in the field. The circuitry will automatically read these settings and incorporate them into its performance. LUBRICATION PROGRAMMING Turn the “Mode Set” switch to the appropriate mode that is to be changed or set (See Programming SLU Control Board diagram). Increase or decrease the number on the digital display to the desired value by pushing the “Reset On-Off” switch up or down. When all modes are set; return “Mode Set” switch to “0” for normal operation.

4

SECTION V Lubricator Indicators The Castrol LubeCon lubrication system is continually monitoring its user programmed settings. EXTERNAL LIGHTS ON CENTRALIZED PUMPING STATION: L1. Clear Light - Indicates power to the unit. This light should be on at all

times, except when power is removed from the unit. L2. Amber Light - Indicates that a lubricator is requesting a lubricant supply

from the pump. The pump and motor will operate during those times. The light (and pump) will automatically shut off when the lubricator no longer requests lubricant.

L3. Red Light - Indicates that the lubricator reservoir is out of lubricant. This

light also indicates that the pump and motor has automatically shut down to prevent operation of the pump when it is dry. This light will automatically be turned off and the pump returned to an operative condi-tion when the lubricant reservoir is refilled.

LIGHT EMITTING DIODE (LED) INDICATORS LOCATED ON THE LUBRICATORS’ CIRCUIT BOARD PANEL: L4. Yellow LED - Indicates lubricator is in an “On Cycle.” L5. Green LED - Indicates the dispensing time for the #1 dispenser. The

length of time that the LED is “On” is the length of time the solenoid valve(s) is activated. (Adjustable)

L6. Green LED - Indicates the dispense item for the #2 dispenser. The length

of time that the LED is “On” is the length of time the solenoid valve(s) is activated. (Adjustable)

L7. Green LED - Indicates the dispense time for the #3 dispenser. The length

of time that the LED is “On” is the length of time the solenoid valve(s) is activated.

5

OVERALL DIMENSIONING6&12 GAL.CENTRAL SYSTEM

SECTION VI Installation M1. Selecting the lubricator’s location

Choosing the proper location for your lubrication system is the first step in the Installation procedure. Consider the following suggestions:

1. If possible, locate the lubricator on the conveyor after the conveyor has been

unloaded. This practice prevents possible contamination of a production part. 2. If ovens or washers are present on the conveyor, then locate the lubricator on

the conveyor after the conveyor exits from the oven as far from the washer as possible. The lubricant will then be applied to the conveyor for the greatest amount of time. Dry film lubricant should have enough time for the lubricant to dry before entering an oven or dryer.

3. The lubricator should be mounted where the conveyor chain is stable, under tension, and away from harsh operating conditions; such as water spray or high temperatures.

4. Place the Lubricant Pumping Station away from a main traffic area. Protect the unit from lift truck traffic by locating it near a protective structural column or in a corner.

M2. Installation of a 6&12 gal. units

After placing the SLU pumping station at the desired location, only the lubricant supply line and a low voltage control cable needs to be connected to the pumping station. The pumping stations have been pre-wired and tested, so that no internal connections are required except for those indicated.

1. Attach the lubricant supply line by pushing the tubing firmly into the quick

connect fitting located next to the pump motor. Push the tubing in as far as possible. Then, attempt to pull the tubing out. This operation will seal the connection. The fitting is a reusable, self-locking fitting. Should the tubing have to be removed at any time, push in on the fitting’s collar while pulling out on the tubing.

2. The incoming power source (115 VAC) must be connected to the pumping station’s controller as shown on the controller’s panel on the diagram inside of the controller’s door.

3. A lubricant supply line and a low voltage control cable must be installed to connect the SLU pumping station to the lubricator.

7

SECTION VI Installation (continued) M2. 3. (Continued)

The lubricant supply line is usually a flexible nylon line with a diameter of 1/4”. Steel or copper tubing should be used if high temperatures exist. The control cable supply line is usually fastened overhead, among the structural components of the building. Wire tie-wraps and beam clamps are common methods employed to fasten the supply lines to the existing structures. Avoid sharp bends in the lubricant supply line; sharp bends could prevent flow of lubricant and prevent proper operation of the system. When installing the lubricant supply lines, tape the ends of the tubing closed to prevent contamination. Leave an additional two feet of lubricant supply line and cable at each end until the final connections are made. 4. The pumping station will not operate if the lubricant reservoir is empty.

A flashing red light on the pump controller will indicate this fault condition.

M3. Mounting of the Lubricator

Select a straight, level section of the conveyor’s track or I-beam to mount the lubricator. The section chosen must be free of obstructions, a minimal amount of vibration, and the bearings should be rolling smoothly through this section of the conveyor. The same is true if using a lubricator that is pre-mounted on a section of I-beam. Preparation of the conveyor section is for mounting the Castrol LubeCon lubricator may require access holes and or slots. These access holes and slots allow access for the dispensing tubes and their protective plates. All Castrol LubeCon lubricators are supplied with mounting hardware and brackets. The I-beam preparation instructions given are for the lubrication of both trolley bearings and chain pins. Omit any portion of these instructions that do not apply to your particular lubricator.

8

SECTION VI Installation (continued) M4. Connecting the Electrical Power

The incoming control cable (24 VDC) must be connected to the lubricator’s terminal strip as shown on the wiring schematic and on the inside cover of the lubricator’s door. The SLU Pumping Station should also be connected to a 115 VAC power source. This connection is also shown on the wiring schematic and inside the Pump controller’s door.

IMPORTANT: Incoming power sources to the pumping station should be clean, continuous and without interruptions. 120 VAC @ 15 amps, wire size no smaller than local code minimum LUBRICATOR M5. Start-Up Procedure and Initial Settings Step by Step

1. Weld pre-mounted lubricator track section into conveyor line or mount lubricator onto existing conveyor track.

2. Place the pumping station “off—on” switch in the “off” position. 3. Connect 24 VDC control cable to the lubricator per Section VI M4 (also

Section III). 4. Fill reservoir with the proper lubricant. 5. Set all lubricator settings (Section IV). 6. Turn the pumping station “off—on” switch to “on”. The pump motor

will start, the external power indicator and the external pump indicator will light, and the lubricator will not dispense lubricant each time the detection switch is activated, if it is in a lubrication cycle.

NOTE: Allow sufficient time on the initial start-up for the pump to prime and air to be flushed out of the capillary lines. Dispensing tube outlets from any one valve should be at the same height. This prevents the lower tubes from dripping due to a higher tube outlet venting air into the line.

9

SECTION VI Installation (continued) M5. (continued)

7. After the dispensing tubes finish discharging air from the system, set the Relief valve pressure located on the pump unit. This adjustment allows the increase or decrease of the lubricant line pressure, to get the lubricant to the remote lubricators.

8. Check to see that the detection switches are being activated by only the appropriate part on the trolley bearings or chain link.

9. Aim the dispensing tubes to place the lubricant into the correct points desired. Lead the chain slightly so that any lubricant “tail” that may exist will not drop through an opening in the chain.

M6. System Maintenance

1. Although your Castrol LubeCon lubricator is virtually maintenance free, it is advisable to routinely check to see that the lubricant being dispensed is hitting the correct spot. If not, readjust the dispensing tubes so that they will hit the desired points. Service and extended warranties are available through your Castrol LubeCon representative.

2. Clean (or replace) all lubricant filters every two years, or as required. 3. Check for visible damage caused by the conveyor or debris that the

conveyor may have dragged through the lubricator. 4. Keep the lubricant reservoir filled. Routine topping off of the reservoir

prevents automatic shutdown caused by an empty tank. 5. Visually inspect detection switches to ensure that they are being

activated properly. An LED indicator is provided on each detection switch for this purpose.

6. Visually inspect to ensure that all dispensing tube outlets, from any one solenoid valve, are to be at the same level. This will prevent the lower tubes from dripping.

7. Keep the dispensing tubes as short as possible. Excessive lengths decrease the lubricant velocity as it leaves the dispensing tube ends, and may create a slight “tail”.

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SECTION VII Limited Warranty Your Castrol LubeCon lubrication system is pre-tested and guaranteed to be in perfect condition when it leaves our factory. The system is fully guaranteed against defective materials or workmanship for a period of twelve (12) months from the date of purchase. Any portion of the lubrication system which should fail for either of the above reasons (excluding) normal replacement parts such as indicator light bulbs, fuses, etc., and still within the warranty period will be repaired or replaced at our option, if the service is performed by a Castrol LubeCon serviceman. All defective parts returned for warranty service will be fully inspected to determine cause of failure before warranty is approved. Our warranty is limited to the obligation to repair or replace our equipment only. This warranty gives you specific legal rights and you may have other rights which vary from state to state. The Castrol LubeCon warranty will be void if any of the following conditions are found to exist relative to the Castrol LubeCon equipment:

1. Electronic components tampered with, or short circuited. 2. System abuse by customer; customer’s equipment malfunctions; or

customer’s equipment is maladjusted. 3. Damage caused from voltage or environmental conditions exceeding

the specified viscosity range, or operating parameters.

Replacement parts and field service are available to the customer should they so desire. Contact the Castrol office (1-800-582-3266 or 231-689-0002) for service scheduling, rate and/or replacement costs.

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