19_670864alemitecls1000

670864 SER 387780

Revision (11-06)

Service Guide 387780

Alemite Corporation

167 Roweland Drive, Johnson City, Tennessee 37601

www.alemite.com

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.

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.

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

SER 387780 Centralized Lubrication System Controller

Revision (11-06) 2 Alemite Corporation

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

Centralized Lubrication System Controller SER 387780

Alemite Corporation 3 Revision (11-06)

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.

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

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.

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.



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]”



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.



Idle Time

“Idle time”

“XXXX [idle units]”

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 half-

cycles 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.



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.



Alarm Time

“Alarm Time”




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”



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”



Press the ENTER key to save the Pump Cycles value and move to the Power Up Mode field.



Power Up Mode

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.



Lube (with 00.5 or more cycle counts)

“Lube”

“XX.X counts” (or “strokes”)

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”


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.



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.

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.

Manual

Run Switch



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.



Figure 3: Silkscreen of the CLS 1000 Connector Descriptions



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



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



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



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



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



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



Machine Cycle Input

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



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



Figure 15: Lube Cycle Indicator Connection using Dry Contact Switch

Figure 16: Lube Cycle Indicator Connection using NPN Proximity Switch



Figure 17: Lube Cycle Indicator Connection using PNP Proximity Switch



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



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



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

PNP NC



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



Figure 22: 115 VAC Power, Machine Cycle Dry Contact, Lube Cycle Dry Contact, High Pressure Dry

Contact NO, Low Level Dry Contact NO

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