LC 502 controller EN Operating instructions for DuoFlex ... · (ProFlex, MonoFlex, or DuoFlex) and...

1

2

3

ENLC 502 controller for DuoFlex centralized lubrication systems

Operating instructions

Version 02

EN

Table of contents

1. Display and control elements of control screen 4

1.1 LC502 control screen 4

2. Display, operating, and service menus 6

2.1 Main menu 6

2.1.1 Main menu 7

2.2 Info - Information mode 8

2.3 Conig.-Conigurationmode 103. Menu structure 12

3.1 Menu structure of Info 12

3.2 MenustructureofConigurations - View 13

3.3 MenustructureofConigurations - Edit 14

3.4 Menu structure of Status 15

4. LC502- factory setting of a DuoFlex centralized lubrication system 16

4.1 Generalconigurationofasingle-line DuoFlex centralized lubrication system withtwoanalogpressuresensors 16 4.1.1 Systemdesign 17 4.1.2 Example,programmingofadual-line centralized lubrication systemwith one

mainlineandanalogpressuresensors 20 4.2 GeneralconigurationofaDuoFlex central lubrication system with

onemainlinewithdifferentialpressure switchDDS50/1,version400VAC 21 4.2.1 Systemdesign 22 4.2.2 Exampleofprogrammingasingle-line dual-line centralized lubrication system

withdifferentialpressureswitch DDS50/1,halfcyclemode 25 4.3 Generalsysteminputsofadual-line centralized lubrication system 26

4.4 Factory-setassignmentofthesystem inputs 30 4.5 Generalsystemoutputsofadual-line centralized lubrication system 31

4.6 Factory-setassignmentofthesystem outputs 33 4.7 Settingsonlubricationline1 34 4.7.1 Activationofthedwelltime 34

Table of contents

5. Adjustment options available to the customer 35

5.1. Assignmentinput1/input2 35 5.1.1 Settingofthedifferentialpressure switch,analogordigital,andits polarity 35 5.1.2 Inputofthechangeovervalueofthe analogdifferentialpressureswitch 35 5.2. Settingsofinput3 38 5.2.1 Polarity delay extension 38

5.3. Input4settings 39 5.3.1 Typeofilllevelmonitoring 39 5.3.2 Filllevelmonitoringpolarity 39 5.4 Settingtheoutputs 41 5.4.1 Valvecontrolpolarity 41 5.4.2 Erroroutputpolarity 41 5.5 Settingthepause,runanddwelltimes43 5.6 Specifyingthesystemmodehalfcycle/ full cycle 46

5.7 Activation/deactivationofthedelay extension 48

EN

6. Status display 50

6.1 Status-Displayofcurrentdevicestatus50 6.2 Lub - Runtimes of the lubrication process 51 6.3 Extractingtheactivatedinputs 51 6.4 Displayactiveerrors 56 6.5 IO State - Read electrical states of inputsandoutputs 57 6.6 IO Conn. - read connection states of inputsandoutputs 58 6.7 Readambienttemperatureonthe controlunit 597. Basic settings 60

7.1 Basic initialization of control unit 60

7.2 Control unit reset function 61

7.3 Resettingtheuserpasswordforthe controlunitforconigurationchanges 62

8. Electrical connections/wiring 63

8.1 Control cubicle 63

8.2 TerminalstripX1powersupply 64 8.2.1 Powersupply24VDC 64 8.2.2 Powersupply230VAC 64 8.2.3 Powersupply400VAC 64 8.3 TerminalstripX2assignmentofthe inputswithanalogpressuresensor 65 8.3.1 TerminaldiagramX2assignmentofthe inputswithanalogpressuresensor 66 8.3.2 TerminalstripX2assignmentofthe inputswithDDS50/1 67 8.3.3 TerminaldiagramX2assignmentofthe inputswithDDS50/1 68 8.4 TerminalstripX3,outputs 69 8.4.1 Outputs24VDC 69 8.4.2 Outputs230/400VAC 69

9. Operational and pump faults 70

9.1 Operationalmalfunctions 70 9.1.1 Generalinformation 70 9.1.2 Systemerrors 70 9.2 Displayfaults 70 9.3 Deletefaultnotiication 70 9.4 Faulttypes 71 9.5 Errornotiication 7210. LC502 menu displays 74

11. Technical data of the LC502 control unit 80

11.1 BasicsettingoftheLC502 80

Table of contents

EN

Display and control elements of control screen

Drawing Description Function

Display Menu display Displays values and parameters Error notification

Error LED Displays fault notification Red LED flashes = error detected Red LED lights up = fault on a signal input, no error detected on pump control unit (error is outside pump)

PAUSE LED Indicates pause time Yellow LED lights up = active pump pause time on at least one main line

CONTACT LED Indicates contact time (pump operation) Green LED lights up = active pump runtime

1 = Output 12 = Output 2

Indicates pump output 1 to 2 LED on output 1 or 2 lights up = pump output 1 or 2 is switched on. Lubricant is delivered via the indicated line (1 or 2)

3 = Inputs Indicates all signal inputs LED lights up = signal change on input port The LED lights up for approx. 1 second each time the signal on the input port changes.

ENTER key Confirm selection Confirm entry and values

2

1

3

1. Display and control elements of control screen

1.1 LC502 control screen

The display and control unit is protected from water splashes and mechanical damage by a transparent plastic cover. The cover must be removed to program the unit and then remounted afterwards.

LC502 control screen

1

2

3

1.Displayandcontrolelementsofcontrolscreen

EN

Display and control elements of control screen

Symbol Description Function

Operator keys Operator keys Go to menu selection (navigation) Edit numerical values

Operator keys Operator keys for menu selection (navigation)(arrow key up/down/left) Go to the selected menu based on direction of arrow

Operator keys for editing numerical values(arrow key up/down) The numerical value is incremented/decremented based on direction of arrow

Operator key for editing numerical values(arrow key right) Press the key to edit the selected value

DK key Pressing during pause time triggers an interim lubrication

Error notifications are acknowledged and deleted

1.Displayandcontrolelementsofcontrolscreen

EN

1

2

3

Device display - Base menu

2.1 Main menu

Thecontrolunit'sdisplayhasthreerowsofeightcharacterseach.Onlythreeoptionsareshowninmenuwindowscontainingmorethanthreeavailablechoices.Pressthekeystoviewfurtheroptions.Configuringasettingonthedeviceinvolvesconsecutivelyopeningmultiplemenuwin-

dows.Thecurrentdevicesettingisthenshownonablackbackground.Notallpossibleoptionsaredisplayedinthesettings.Onlysettingsthatareavailableandpermittedfortheselecteddevicemodel(ProFlex,MonoFlex,orDuoFlex)andthecur-rentdevicesettingsareshown.Thefirstmenulevelshowslanguageselection.Thelanguagethatiscurrentlyselectedflashes.Uponconfirmation,themainmenuwillbedisplayedintheselectedlanguage.

2. Display, operating, and service menus


EN

2.1.1 Main menu

Device display - Main menu

Themainmenushowsthefollowingoptions: Device-specificinformation Deviceconfiguration

Status information

Note!

TheServicemenuselectionispassword-protectedandcanonlybeaccessedbySKFemployees.


Base and main menu

Step Key Display Description

1 Entry mask/language selectionThe active language flashes by default.

Press <arrow key up/down> to select a different language.

2 Main menu

Service

English

German

Info

Conig

Status

Main menu items

Display Description

Info Displaydevice-speciicdatasuchasserialnumberorirmwareConfig.uration ParametersettingsStatus DisplaycurrentstatusofcontrolunitService ServicemenuMenulevelonlyenabledforSKFservicepersonnel

1

2

3

EN

2.2 Info - Information mode

Information mode is used to query the hard-

ware identification code and the run times

storedthusfarforthesystem,motor,anderrtime(systemruntime,motorruntime,errortime).

Note!

Novaluescanbeenteredormodiiedininformation mode.

Selection in information mode is per-formed by briely pressing one of the

keys.

Display

1

2

3


EN2. Display, operating, and service menus

Information mode


1 Entry mask/language selectionThe active language flashes.Press <arrow key up/down> to select a different language Press the ENTER key to move to the main menu.

2 Main menuPress the ENTER key to go to the Info menu.

3 Info menu

You can switch between menu items using <arrow key up> and <arrow key down>.

Press the ENTER key to jump to the respectively selected sub-menu.

Press the ENTER key.

4 Serial number Each control unit has an assigned serial number that can be viewed by pressing the ENTER key.Firmware This is the current version number of the software and can be viewed by pressing the ENTER key.Sys time This displays the total running time (on-time) of the control unit in hours, minutes, and seconds. Mot time This displays the total runtime of the pump motor in hours, minutes, and seconds. Err timeThis displays the total time of the current error (if present). If there is currently no error state, the display shows the sum time of all errors detected thus far.

Press the <arrow key left> to return to the main menu Press <arrow key left>.

Mot time

Error time

English

German

Info

Conig

Status

Serial No.

Firmware

Sys time

Sys time

ØØØØØhØØm ØØs

Mot time


Error time



2.3 Conig.-ConigurationmodeConfigurationmodeisstartedbyselecting<Config.>inthemainmenuandpressingtheENTERkey.Firstyouneedtospecifywhetheryouwanttoedittheconfigurationdataorviewitonly.Ifyouwanttoedittheconfigurationdata,apasswordisrequested.

Note!

Afterenteringthecorrectpassword,allcurrentlyrunninglubricationproce-

duresarestoppedandtheconigurationmode starts.

Iftheconfigurationdatawillbeviewedandnotmodified,the<Config.menu>willappearuponconfirmationbypressingtheENTERkey. Nochangescanbemadeinthismode.

Selection in coniguration mode is performed by briely pressing one of the

keys.

Configuration menu, table 1 of 2


1 Entry mask/language selection

The active language flashes.Press <arrow key up/down> to select a different language Press the ENTER key to move to the main

menu.

2 Main menu

Select “Config.” using the arrow key. Press the ENTER key to go to the Config.

menu.

3 Config. menu

DisplayPress the ENTER key to go to the Configuration menus. Here you can call up the configurations for:

System Settings Inputs Outputs

for viewing. The current configuration is indicated by flashing.Data cannot be entered or changed in display mode.

English

German

Info

Conig

Status

Display

Edit


Configuration menu, table 2 of 2


4 Edit Press the ENTER key to go to the password prompt menu. Press the ENTER key.

5 Password menu

The following password prompt prevents modifications by unauthorized persons. Press <arrow key up> to increment the number by 1, up to 9. Press <arrow key down> to decrement the number by 1, down to 0. Press <arrow key right> to move to the next password number (max. 7). Press the ENTER key. Pressing the ENTER key gives access to the following configuration menus

or: Press “arrow key left” to cancel entry and return to the main menu.

6 Configuration sub-menu selection

Press the ENTER key to go to the Config. menu.

Password

00000000

New Pwd

Outputs

Default

Reset

System

Settings

Inputs

DisplayEdit

EN

InfoConfig.Status

Service

1

23

SerialFirmwareSys time

Mot timeErr time

Sys timeØØØØØhØØm ØØ s

ØØØ-ØØØ-ØØØ-LØv1.Ø.a.1

ØØØØØØØØØØØØ

Mot timeØØØØØhØØm ØØ s

Err timeØØØØØhØØm ØØ s

English

Deutsch

3. Menu structure

3.1 Menu structure of Info

3. Menu structure

EN

3.2 MenustructureofConigurations-View

3. Menu structure

InfoConfig.Status

Service

1

23

ViewEdit

SystemSettingsInputs

Outputs

Pro FlexMono FlexDuo Flex

Line 1

Input 1Input 2Input 3

DisabledPCCountLevel SW

p-switchExtern DKExtDelay

Input 4

ExtStop

FunctionPolarity 2)

MechanicAnalogueDigital

FunctionType 1)Polarity 2)

TimeValvesp-Switch

PauseRuntimeDwell time

PauseØØØØØhØØm ØØs

Valve 1Valve 2

Runtime ØØØØØhØØm ØØs

Dwell time ØØØØØhØØm ØØs

Output 1Output 2

NoneInput 3 (4)

p-Diff.Cyc. TypeDelayer

Output 1 Output 2 ErrorOut

Valve

N OpenN Closed

N OpenN Closed

N OpenN Closed

English

Deutsch

Input 1

p-switch 1p-switch 2Dwell

Input 2

DisabledEnabled

Halfcycles.Fullcycles

p-switch

AnalogueDigital

N OpenN Closed

FunctionType 1)Polarity 2)

p-Diff.

ØØØØØ

p-Aktive

p-AktiveØØØØØ

1) The <Type> display menu is only shown (enabled) when the fill level indicator <Level SW> is activated.

2) The <Polarity> display menu is only shown (enabled) when monitoring devices’ inputs are enabled for delay extension <ExtDelay> or stop input <ExtStop> or when valve outputs <Valve> are enabled.

EN

3.3 MenustructureofConigurations-Edit

Passwort ØØØØØØØØ

CancelSave

InfoConfig.Status

Service

1

23

ViewEdit

SystemSettings.Inputs

OutputsDefaultReset

Pro FlexMono FlexDuo Flex

Line 1


DisabledMCCountLewel SW

p-switchExtern DKExtDelay

Input 4

ExtStop

FunctionPolarity2)

MechanicAnalogueDigital

New PWD

FunkctionType 1)Polarity 2)

CancelSave

ResetØØØØØØØØ

TimeValvep-switcht

PauseRuntimeDwell time

PauseØØØØØhØØm ØØs

Valve 1Valve 2

Runtime ØØØØØhØØm ØØs

Dwell time ØØØØØhØØm ØØs

Output 1Output 2

NoneInput 3 (4)

p-Diff.Cyc. typeDelayer

Output 1Output 2ErrorOut

Ventil

N OpenN Closed

N OpenN Closed

N OpenN Closed

English

Deutsch

Input 1

p-Swit 1p-Swit 2Dwell time

Input 2

DisabledEnabled

Half Cycle.Full Cycle

p-switch

AnalogueDigital

N OpenN Closed

FunkconType 1)Polarity 2)p-Active

p-aktivØØØØØ

p-Diff.

ØØØØØ

1) The <Type> display menu is only shown (enabled) when the fill level indicator <Level SW> is activated.

2) The <Polarity> display menu is only shown (enabled) when

monitoring devices’ inputs are enabled for delay extension <ExtDelay> or stop input <ExtStop> or

when valve outputs <Valve> are enabled.

3. Menu structure

EN

3.4 Menu structure of Status

3) For a list of possible fault signals <Errors>, see Chapter 5, Operational and pump faults.

3. Menu structure

LubErrorsIO state

IO conn.Temp.

Line 1

Standard programming Input 3

Standard programming Input 4

LubtimeInputs

Runntime/ Pause ØØØØØhØØm ØØs


Input 4

Output 1 (2)None3)

1 2 3 4 M 1 20 0 0 0 0 0 0

1 2 3 4 M 1 2

Temp.ØØ °C

InfoConfig.Status

Service

1

23

Digitalp-switchRC Ø

Menu pressure switch

MC CyclesEX ØRC Ø

Menu machine contact

Level SWEX ØRC Ø

Menu level switch

External DK

Ø

Menu external pressure contact

ExtDelay

Ø

Menu pause ExtDelay

ExtStop

Ø

Menu ExtStop

Input 1Output 1Output 2

English

Deutsch

EN

4.1 Generalconigurationofasingle-lineDuoFlexcentralizedlubricationsystemwithtwoanalogpressuresensors4. LC502- factory setting of a DuoFlex centralized lubrication system

Thefollowingdescriptionappliestoa230VACtwo-line centralized lubrication system for in-

dustrial use with one lubrication line. The

LC502 control unit (1)isinstalledinaDuoFlexcontrolcabinet,withloadunitandpowersup-

plyforthepumpmotorandtheconnectedvalvesandsensors.Onegreasesupplyline(2)andonegreasere-

turn line (3)areflangedtothepumphousingofthedualline-pump.TheseareflangedwiththeirrespectiveendstoamodelSSY203elec-tricalchangeovervalve(4).Two main feed lines (5)(6)proceedfromtheSSY203electricalchangeovervalvetothedu-

al-linedistributorsindownstreamalignment(7).Aheadofeachofthelastdual-linedistrib-

utorsofmainfeedline1andmainfeedline2,ananalogpressuresensor(8)(9)hasbeenfit-tedthattransmitsasignalcorrespondingtotheexistingpressuretothecontrolunit(thecontrolunitcomparesthetwosignals). The fill level monitoring is carried out by a fill

level switch located in the pump reservoir. This switches the pump off when the minimum fill level has been reached.

The system version is suitable for greases up to NLGI Grade 3.

1

2

3

4.LC502-factorysettingofaDuoFlexcentralizedlubricationsystem

Example of a single-line DuoFlex dual-line centralized lubrication system

EN

4.1.1 System design Seepages16,18and19.Afterthepausetime,thepumpdeliverslubri-cantthroughthegreasesupplyline(2)totheSSY203electricalchangeovervalve(4).Dependingonthepositionofthechangeovervalve(4),thelubricantisthenconveyedon-

wardthroughmainfeedline1(5)ormainfeedline 2 (6)tothedual-linedistributors(7).Withcontinuousdelivery,thepressureintheactuated main feed line increases until the re-

sistancesinthesystemhavebeenovercome.Afterwards,thecontrolandmeteringpistonsof the dual-line distributors are actuated.

Lubricantisdispensedthroughthebranchlines (10)tothelubricationpointsorprogres-sivefeedersindownstreamalignment(11).Onceallofthedistributorshavedispensedtheir quantities of lubricant (control and me-

teringpistonsareintheirendpositions),thefirsthalfoftheconnectedlubricationpointsinsection"A"hasbeensuppliedwithlubricant.Becausethepumpcontinuestodeliverlubri-cant,afurtherpressureincreaseensues.

Onceapre-defineddifferentialpressurehasbeenreachedbetweenthepressurizedanddepressurizedmainfeedlines(analogpressuresensors (8)/(9)),aswitchingsignalensuesviatheLC502.Thechangeovervalve(4)switchesover,whichmeansthatthepreviouslypressur-izedmainfeedlineisdepressurizedwhilepressureisbeingbuiltupinthepreviouslyde-

pressurizedmainfeedline.Thecontrolandmeteringpistonsareactuatedonceagain,lu-

bricantisdispensedonceagainatthistimetothelubricationpointsortotheprogressivefeedersindownstreamalignment(11)ontheoppositesideofthefeeders,section"B".Oncethisprocesshasbeenrunthrough,onefullcycle(2xhalf-cycles)iscompleted.Thepumpfilllevelismonitoredbyafilllevelswitch.

Errornotificationscanbeshownviaanexter-nalindicatorlamp(connectedtoerroroutput,inadditiontothedisplay).


EN

1

2

3

Legend

1 Unit with LC502

2 Grease supply line

3 Grease return line

4 SSY203 electrical changeover valve

5 Main feed line 1

6 Main feed line 2

7 Dual-line distributor

8 Analog pressure sensor for main feed line 2


10 Secondary line

11 Progressive feeder with lubrication lines


Example of a DuoFlex dual-line centralized lubrication system with one main line, external changeover valve and two analog pressure sensors

EN

Legend

1 Unit with LC502 and changeover valve

2 Main feed line 1

3 Main feed line 2




7 Secondary line



1

2

3

Example of a DuoFlex dual-line centralized lubrication system with one main line, integrated changeover valve and two analog pressure sensors

EN

4.1.2 Example, programming of a dual-line centralized lubrication system

with one main line and analog pressure sensors

Existing components and factory settings

The control unit is factory-set to DuoFlex

(dual-linecentralizedlubricationsystem).The

pumpmonitoringandpumpfilllevelmonitor-ingareperformedbyafilllevelswitch, the

pressureinbothmainfeedlinesismonitoredbyoneanalogpressuresensoroneachline.These are mounted ahead of the last dual-line

distributor.

The DuoFlex system with one main line de-

scribedinthefollowingconsistsprimarilyofthecomponents: 230VACdualline-pumpunitwith changeovervalve

LC502 control unit, factory prepro-

grammedfor: -DuoFlexsingle-linecentralizedlubrication system

Pump:

<Input4> =><Function>=><Filllevel>=>

<Type>=><Mechanics>(Filllevelswitchforminimumdisplay) <Polarity>=><NCcontact>(Default) <Type>=>>capacit.>FilllevelswitchforMinLubrication line 1:

<Input 1> => <Function>=><p-switch>=> <Type>=> <Digital>=><Polarity>=><NCcontact>(pressuresensor,mainfeedline1) or: <Type>=> <Analogue>=>↵ <Value>

<Input 2> => <Function>=><p-switch>=> <Type>=><Digital>=><Polarity>=><NCcontact>(pressuresensor,mainfeedline2) or: <Type>=><Analogue>=>↵<Value><Input 3> => <Function>=><ExtDelay>=><Polarity>=><NCcontact><Output 1> =><Valve>=><Polarity>=><NOcontact>(changeovervalve,mainfeedline1) <Output 2> =><Valve>=><Polarity>=><NOcontact>(changeovervalve,mainfeedline2) lubrication line:

dual-line distributor

oneanalogpressuresensorpermainfeedline

for FF/FB pump

for FK pump


EN

4.2 GeneralconigurationofaDuoFlexcentrallubricationsystemwithonemainlinewithdifferential pressure switch DDS50/1, version 400 VAC

SeeFigure,page23/24

Thefollowingdescriptionappliestoa400VACdual-line centralized lubrication system for in-

dustrial use with one lubrication line.

The LC502 control unit (1)isinstalledinaDuoFlexcontrolcabinet,withloadunitandpowersupplyforthepumpmotorandtheconnectedvalvesandsensors.Dependingonthepumpversion,thechange-

overvalvedescribedbelow(4)canbeattacheddirectlytothepump(greaselubricationpumpunitFK,modelFK2)or,inthecaseofsystemswithhighoperatingpressure,separatedfromthe(greaselubricationpumpunitFK,modelFK3).Inthecaseofthelatterversion,onegrease

supplyline(2)andonegreasereturnline(3)areflangedtothepumphousingofthedualline-pump.Thesearefastenedwiththeirre-

spectiveendstotheelectricalchangeovervalve(4)ofthemodelSSY203. Thefunctionaldescriptionofthechangeovervalveisthesamewithbothvariants.Two main feed lines (5)(6)proceedfromtheSSY203electricalchangeovervalvetothedu-

al-linedistributorsindownstreamalignment(7).AmodelDDS50/1differentialpressureswitch (8)isfittedaheadofthelastdual-linedistributor. This contains two NO contacts.

Thedifferentialpressureswitchmeasuresthedifferentialpressurebetweenmainfeedlines1and2.AsignalissentontotheLC502whenadifferentialpressureof∆p=50barisreached.Fill level monitoring is performed by an ultra-sound sensor located in the pump reservoir.

The ultrasound sensor has two switching points. When the fill level minimum is reached, switching point 1 is assigned the task of pass-ing on a signal to the controller, which then switches off the pump. When the maximum fill level is reached, switching point 2 is assigned the task of passing on a signal to the system control unit. This means that an external filling pump can be operated with both signals per system con-trol unit.

The system version is suitable for greases up to NLGI Grade 3.


EN

4.2.1 System design SeeFigure,page23/24.Afterthepausetime,thepumpdeliverslubri-cantthroughthegreasesupplyline(2)totheSSY203electricalchangeovervalve(4).Dependingonthepositionofthechangeovervalve(4),thelubricantisthenconveyedon-

wardthroughmainfeedline1(5)ormainfeedline 2 (6)tothedual-linedistributors(7).Withcontinuousdelivery,thepressureintheactuated main feed line increases until the re-

sistancesinthesystemhavebeenovercome.Afterwards,thecontrolandmeteringpistonsof the dual-line distributors are actuated.

Lubricantisdispensedthroughthebranchlines (10)tothelubricationpointsorprogres-sivefeedersindownstreamalignment(11).Onceallofthedistributorshavedispensedtheir quantities of lubricant (control and me-

teringpistonsareintheirendpositions),thefirsthalfoftheconnectedlubricationpointsinsection"A"hasbeensuppliedwithlubricant.Becausethepumpcontinuestodeliverlubri-cant,afurtherpressureincreaseensues.

Onceapermanentlysetdifferentialpressurelevelof50barhasbeenreachedbetweenthepressurizedanddepressurizedmainfeedlines,theDDS50/1differentialpressureswitchsendsaswitchingsignaltotheLC502.Thechange-

overvalve(4)switchesover,whichmeansthatthepreviouslypressurizedmainfeedlineisdepressurizedwhilepressureisbeingbuiltupinthepreviouslydepressurizedmainfeedline.Thecontrolandmeteringpistonsareactuatedonceagain,lubricantisdispensedonceagainatthistimetothelubricationpointsortotheprogressivefeedersindownstreamalignment(10)ontheoppositesideofthefeeders,sec-tion "B".

Oncethisprocesshasbeenrunthrough,onefullcycle(2xhalf-cycles)iscompleted.Thepumpfilllevelismonitoredbyanultra-

sound sensor.

Errornotificationscanbeshownviaanexter-nalindicatorlamp(connectedtoerroroutput,inadditiontothedisplay).


EN

Legend

1 Unit with LC502

2 Grease supply line

3 Grease return line

4 SSY203 electrical changeover valve

5 Main feed line 1

6 Main feed line 2


8 Differential pressure switch DDS50/1 for main feed line 1 and main feed line 2

9 Secondary line



1

2

3

Example of a DuoFlex dual-line centralized lubrication system with one main line, changeover valve SSY204 and differential pressure switch DDS50/1

EN

Legend

1 Unit with LC502 and changeover valve

2 Main feed line 1

3 Main feed line 2


5 Differential pressure switch DDS50/1 for main feed line 1 and main feed line 2

6 Secondary line

7 Progressive feeder with lubrica-tion lines


1

2

3

Example of a DuoFlex dual-line centralized lubrication system with one main line, integrated changeover valve and differential pressure switch DDS50/1

EN

4.2.2 Example of programming a single-line dual-line centralized lubrication system

with differential pressure switch DDS50/1, half cycle mode

Existing components and factory settings

The control unit is factory-set to DuoFlex

(dual-linecentralizedlubricationsystem).The

pumpmonitoringandpumpfilllevelmonitor-ingareperformedbyafilllevelswitch, the

pressureinbothmainfeedlinesismonitoredbythedifferentialpressureswitchDDS50/1.The DuoFlex system with one main line de-

scribedinthefollowingconsistsprimarilyofthecomponents: 230VACdualline-pumpunitwith changeovervalve

LC502controlunit,factorypreprogram- medfor: -DuoFlexsingle-linecentralizedlubrication system

Pump:


<Type>=><Mechanics>(Filllevelswitchforminimumdisplay) <Polarity>=><NCcontact>(Default) <Type>=>>capacit.>FilllevelswitchforMinLubrication line 1:

<Input 1>=> <Function>=><p-switch>=> <Type>=><Digital>=><Polarity>=><NOcontact>(DDS50/1,mainfeedline1)<Input 2> => <Function> => <p-switch> => <Type> => <Digital> => <Polarity> => <NO contact> (DDS50/1, main feed line 2)

<Input 3> => <Function>=><ExtDelay>=><Polarity>=><NCcontact><Output 1- =><Valve>=><Polarity>=><NOcontact>(changeovervalve,mainfeedline1) <Output 2> =><Valve>=><Polarity>=><NOcontact>(changeovervalve,mainfeedline2) lubrication line:

dual-line distributor

differentialpressureswitchDD50/1

for FF/FB pump

for FK pump


EN

System inputs, Table 1 of 3


1 Select inputs 1 to 4

use <arrow keys up/down>, select <Inputs> from the configuration menu Press the ENTER key to confirm the selection. Select input 2, input 3, or input 4 using <arrow key down> use <arrow keys up/down> to select one of the inputs 1 to 4 Press the ENTER key to confirm the selection; you will then jump to the following menu for the selected

input Warning! In the case of DuoFlex systems, the function of input 1 and input 2 is already assigned as

that of a pressure sensor (differential pressure switch) (<P-switch>) and cannot be altered. The type (analog/digital) and polarity (NO contact/NC contact) of the two inputs can however be changed.

Press the ENTER key. You will then enter the following Function menu.

The types of the monitoring systems are selected in the following Function menu (input 3 and input 4).After making a selection, you will return to the Function menu. Depending on the monitoring system that is now set, the Type and Polarity menu items will now be enabled in addition to the original Function menu item. Instructions on how to configure it are given in Steps 2.1 to 2.4.

4.3 General system inputs of a dual-line centralized lubrication system

Inputs

OutputsDefault

Input4

Input 1

Input 2

Input 3

Function

TypePolarity

Requirement:

The Configuration menu was pre-selected in the Config menu.


1

2

3

EN



2 Function assignment of the selected input (input 3 or input 4)

The following are available for selection:Disabled = No monitoring system enabledMC Counter = Machine contact counter (external counter)Level SW = Pump fill level monitoringp-switch = Pressure sensorExtern DK = External pressure switch contactDelay extension = control unit goes into delay extension until a new signal is activeExtStop = Error input (function selection and assignment for the line that will be stopped in the event of an error) Press <arrow key up/down> to assign the function to the selected input. Press the ENTER key. Press <arrow key left> to exit the menu After making a selection, you will return to the Function menu. Depending on the input assignment,

the Type, Polarity, and p-Active menu items will be enabled in addition to the Function menu item.

2.1 Assign the <Type> switch type and function <Polarity> to the assigned input

Function Type Polarity p-Aktiv

Disabled - -MC Counter - -Level SW Agitator Agitator rotations (W1) - Mechanic Mechanical fill level switch NO contact/NC contact Capacitive Capacitive fill level switch - Analog Analog fill level switch -p-switch Analog Analog pressure sensor NO contact/NC contact p-Active, see Step 2.4 Digital Digital pressure sensor NO contact/NC contact ExternDK - -ExtDelay - NO contact/NC contactExtStop - NO contact/NC contact

Inaktiv

MC Zähl.

Fill level

p-Switch

Extern DK

ExtDelay

ExtStop

AnalogDigital

Agitator

Mechanics

Capacit.

Grenzw.

Function

Type

Polarity


EN



2.2

or

Assign the <Type> switch type

Select Type using <arrow key down>. Press the ENTER key.

You will enter the (Sensor) Type menu.The following are available for selection:

Analog = Analog fill level sensor, 0-100% display Digital = Digital input

At Level SW:Agitator Agitator rotations (in conjunction with mechanical fill level switch)Mechanic Mechanical fill level switchCapacitive Capacitive fill level switch

Select the type using <arrow keys up/down>. Press <arrow key left> to exit the menu

2.3 Assign <Polarity> of assigned input

Select Polarity using <arrow key down>. Press the ENTER key.

You will enter the NO contact/NC contact menu.The following are available for selection:

N Open = Make function in which the contact closes when the switching point is reached. N Closed = Break function in which the contact opens when the switching point is reached.

Select the type using <arrow keys up/down>. Press the ENTER key. Press <arrow key left> to exit the menu

Function

Polarity

N Open

NC Contact

AnalogDigital

Agitator

Mechanics

Capacit.

Function

Type

Polarity


EN



2.4 Setting the active analog changeover value of the pressure sensor <p-Active> Select p-Active using <arrow key down>. Press the ENTER key.

You will enter the menu for the analog changeover valueAnalog pressure sensors have a value range for their signals. In order for the signal to be processed correctly, a display range from min. 20 to max. 1003 has been established. These sensor values are standardized to the input voltage of the control unit. The recorded values are compared with the stan-dardized values.The selected changeover value p-Active can be edited after the confirmation. The input value is not applied until after a further confirmation (Enter key).

Here you can enter: p-Active = Analog active value (changeover value) on the input

Press <arrow key right> or <arrow key left> to move the cursor position to the adjacent digit. To exit the editor window without saving the current change, press the key again after reaching the last digit.To instead apply the current change, press the ENTER key.

Pressing <arrow key up> increments the selected digit by one.Pressing <arrow key down> decrements the selected digit by one.

Enter the respective changeover value with <arrow keys>; the value must be within the defined setting range of 20 to 1003.

Press the ENTER key to confirm the entry. Go to the end of the line using <arrow key right> or <arrow key left> then press the arrow key again

to exit the menu.

Function

Polarity

p-Active

Analog

Digital

p-Active

ØØØ2Ø


EN

InthecaseofaDuoFlexstandardpump,amaximumof4systeminputsareavailable.Theseareassignedinthedefaultsettingsasfollows:Input 1

Pressure monitoring of main feed line 1

Pressuremonitoringofmainfeedline1takesplaceusingadigitaloranalogpressureswitchmountedaheadofthelastsingle-linedistributor. Thisswitchrecordsthepressurebuild-upwithin main lubrication line 1. Once the

changeoverpressurehasbeenreached,thepressureswitch,dependingonwhetheritisdefinedasNOcontactorNCcontact,passesalongaswitchingsignaltotheLC502controlunitthroughinput1. <Input 1> => <Function> => <p-Switch> =>

<Type> => <Digital> => <Polarity> => <NC

contact> (pressure sensor, main feed line 1)

optional: <Type> => <Analog> => <Value>

Input 2

Pressure monitoring of main feed line 2

Pressuremonitoringofmainfeedline2takesplaceusingadigitaloranalogpressureswitchmountedaheadofthelastsingle-linedistributor. Thisswitchrecordsthepressurebuild-upwithin main lubrication line 2. Once the

changeoverpressurehasbeenreached,thepressureswitch,dependingonwhetheritisdefinedasNOcontactorNCcontact,passesalongaswitchingsignaltotheLC502controlunitthroughinput2. <Input 2> => <Function> => <p-Switch> =>

<Type> => <Digital> => <Polarity> => <NC

contact> (pressure sensor, main feed line 2)

optional::<Type> => <Analog> => <Value>

Input 3

Delay extension (optional)

Thedelayextensionisusedforthetemporaryswitch-off of the DuoFlex dual-line centralized

lubricationsystem(couplingwithasystem). <Input 3> => <Function> => <ExtDelay> =>

<Polarity> => <NC contact>

Input 4

Fill level monitoring of the pump reservoir

Controlandmonitoringofthepumpstakesplacebymeansofafilllevelswitch<Filllevel>. IntheFunctionmenu,thefunctionaldescripti-onofthefilllevelswitchcanbedeterminedusingthemenuitem<Type>toselectbetweenthefilllevelswitchfunctionsAgitator,Mechanics,K(C)CapacitiveorAnalog. Thefunction<Mechanics>(filllevelswitchforminimumdisplay)ispreselectedinthedefaultsettings. <Input 4> => <Function> => <Fill level>,

Type <Agitator> or <Mechanics> or <Capacit.>

or <Analog>

4.4 Factory-set assignment of the system inputs


EN

4.5 General system outputs of a dual-line centralized lubrication system

System outputs, Table 1 of 2


1 Selecting output 1, output 2, or error output

Select outputs using <arrow key down> Press the ENTER key; you will then enter the following outputs menu Press the ENTER key; you will the enter the following Output 1 menu

or: You can switch the output menus between output 1, output 2, and error output using <arrow keys up/

down>. Select between output 1 and output 2 using <arrow keys up/down> Note! The error output has a different menu structure than outputs 1 and 2. This is described in Step 3.

Press the ENTER key; you will then enter the following Function menu

The <Valve> function has already been activated (changeover valve) for output 1 and output 2 in the following Function menu.In the case of DuoFlex dual-line centralized lubrication systems, the changeover valve <Valve 1> is intended for outlet 1 for main feed line 1, while for outlet 2 the changeover valve <Valve 2> is intended for main feed line 2.Furthermore, the menu item <Polarity> is also added. Its setting is described in Step 2.1 (Polarity).

InputsOutputs

Default

Output 1

Output 2

ErrorOut

Function

Polarity


Requirement:

The Configuration menu was pre-selected in the Config menu.1

2

3

EN

System outputs, Table 2 of 2


2 Activating the changeover valve

You will enter the menu for activating the changeover valve. In the case of DuoFlex centralized lubrica-tion systems, outlets 1 and 2 are specified for the <Valve> function.

Valve = changeover valve Press <arrow key left> to exit the menu

2.1 Polarity of the changeover valve



N Open = Make function in which the contact closes when the switching point is reached. NC contact = Break function in which the contact opens when the switching point is reached.


3 Polarity of the error output Select error output using <arrow key down> Press the ENTER key; you will then enter the following Error output menu

You can switch the error output function between make function and break function using <arrow keys up/down>.

Choose between make function and break function using <arrow keys up/down> Press the ENTER key. Press <arrow key left> repeatedly. You will return to the Config. menu

Function

Polarity

N Open

NC Contact

Valve

Output 1

Output 2

ErrorOut

NC contact

NO-contact


EN

4.6 Factory-set assignment of the system outputs

InthecaseofaDuoFlexstandardpump,amaximumof2systemoutputsareavailable.Anerroroutputisalsopresentforcontrollingafaultsignalwhichmayarise. Theseareas-signedasfollowsinthedefaultsettings:

Output 1

Changeover valve pressure build-up/pres-

sure relief main feed line 1

Apressurereliefofmainfeedline1andoftheDuoFlexdistributorstakesplacethroughthechangeovervalveatthetimeofthechange-

overprocedure.Pressureisreducedbythere-

turnflowofthelubricantintothepumpreser-voir. <Output 1> => <Function> => <Valve>,

Polarity <NO contact/NC contact>

Output 2

Changeover valve pressure build-up/pres-

sure relief main feed line 2 Apressurereliefofmainfeedline2andoftheDuoFlexdistributorstakesplacethroughthechangeovervalveatthetimeofthechangeo-

verprocedure.Pressureisreducedbythere-

turnflowofthelubricantintothepumpreser-voir. <Output 2> => <Function> => <Valve>,

Polarity <NO contact/NC contact>

Error output

ThepolarityoftheerroroutputasNOcontactorasNCcontactisspecifiedunderthemenuitem<ErrorOut>. <ErrorOut> => <NO contact/NC contact>


EN

<Dwell>Systemswithmonitoringofpressuresensors can be set in such a way that the the

pumprunningtimeisendedearlyafterthesensorsignalforthepressurebuild-upisre-

ceived.Afterwards,thepumpcancontinuetorun for an additional runtime in order to build

uppressurefurther.Thisadditionaltimeisre-

ferredtoasdwelltime.Attheendofthedwelltime,thepumpgoesintothepause.Ifthedwelltimeissetto0,thenthepumpswitchesovertothepausetimeafterthepressurebuild-upsensorsignalhasbeenreceived.

In the case of DuoFlex centralized

lubricationsystems,dwelltimemustbeactivated!

Activation/deactivation of the dwell time


1 Select the <Line1> lubrication line Select the <Settings> menu item using <arrow

key up/down>

Press the ENTER key; you will then enter the following menu for lubrication line 1.

Press the ENTER key; you will then enter the following menu, Parameter adjustment for Lubrication line 1

2 Selection of the pressure switch menu <p-switch> Select the <p-switch> menu item using <arrow

key up/down> Press the ENTER key; you will then enter the

following p-switch menu Select the Dwell menu item using <arrow key

down> Press the ENTER key; you will then enter the

following Dwell menu

3 Select the <p-Active> menu item using <arrow key down> Press the ENTER key.

SystemSettings

InputsLine 1

TimeValvesp-switch

p-swit 1p-swit 2Dwell

disabledenabled

4.7 Settings on lubrication line 1

4.7.1 Activation of the dwell time


Requirement:


2

3

EN

5.1.1 Setting of the differential pressure switch, analog or digital, and its polarity

Differential pressure switch/differential pressure sensor parameters, Table 1 of 3


1 Selection input 1 (or input 2)

The Inputs configuration menu is already selected

Press the ENTER key; you will then enter the following Input menu

Press the ENTER key; you will then enter the following Input 1 menu

Select <Type> using <arrow key down>


Inputs

OutputsDefault

Input4

Input 1

Input 2

Input 3

Thetwoinputs,input1andinput2,arefacto-

ry-alignedtothetwodifferentialpressureswitches(digital)ortothetwodifferentialpressuresensors(analog).Theinputsarecou-

pledwithoneanotherinthesoftware,sothattheassignmentofthefunctionaldescriptionofthedifferentialpressureswitches/sensorsneedonlybemadeatoneinput(input1orinput2).Therespectiveotherinputautomaticallytakesonthesettingthatwasmade. Thetypeofthepolarityofthedifferentialpres-sureswitches/sensors,asNCcontactorNOcontact,musthoweverbesetseparatelyforeachofthetwoinputs.Thesameistrueofthevalueinputsforthetwoanalogpressuresen-

sors<p-Active>.

5.1.2 Input of the changeover value of the analog differential pressure switch

5. Adjustment options available to the customer

5.1. Assignment input 1/input 2

5.Adjustmentoptionsavailabletothecustomer

Requirement:

The Configuration menu was pre-selected in the Config menu.

1

2

3

EN



2 You will enter the (Sensor) Type menu.The following are available for selection:

Analog = Analog pressure sensor, 0-100% display Digital = Digital input, pressure switch

Select the type using <arrow keys up/down>. Press <arrow key left> to exit the menu

3 Assignment of the <Polarity> of input 1 (or input 2)


You will enter the <Polarity> menu.The following are available for selection:

NO contact = Make function, the contact closes when the switching point is reached NC contact = Break function, the contact opens when the switching point is reached


Function

Polarity

N Open

NC Contact

Function

Type

Polarity

Analog

Digital


EN



4 Setting the active analog changeover value of the pressure sensor <p-Active> for input 1 (or input 2)

Select the <p-Active> menu item using <arrow key down> Press the ENTER key.

You will enter the menu for the analog changeover valueAnalog pressure sensors have a value range for their signals. In order for the signal to be processed correctly, a display range from min. 20 to max. 1003 has been established. These sensor values are standardized to the input voltage of the control unit. The recorded values are compared with the stan-dardized values.The selected changeover value p-Active can be edited after the confirmation. The input value is not applied until after a further confirmation (Enter key).

Here you can enter: p-Active = Analog active value (changeover value) at input 1 (or input 2)

Press <arrow key right> or <arrow key left> to move the cursor position to the adjacent digit. To exit the editor window without saving the current change, press the key again after reaching the last digit.Use the ENTER key to confirm the current change, the last changes will be applied

Pressing <arrow key up> increments the selected digit by one.Pressing <arrow key down> decrements the selected digit by one.

Enter the respective changeover value with <arrow keys>; the value must be within the defined setting range of 20 to 1003.

Press the ENTER key to confirm the input. Go to the end of the line using <arrow key right> or <arrow key left> then press the arrow key again

to exit the menu.

p-Active

p-Active

ØØØ2Ø

Function

TypePolarity


EN

5.2. Settings of input 3

5.2.1 Polarity delay extension

Input3isfactory-setfortheextensionofthepausetime.Dependingonthepolarityoftheexternalsignal,theinputissetasNCcontactor as NO contact.

Ifthesignalisactivatedinthepumpruntimeordelaytime,thenthelubricationprocedurewillcontinuetorununtilthebeginningofthepausetime.Afterwards,thepausetimewillbestoppeduntilthesignalisdisabled.Assoonasthesignaliswithdrawn,thepausetimewillrunontotheendoruntilthenextactivationofthesignal.Anewlubricationcycleisstartedattheendofthepausetime.

Setting the polarity for delay extension


1 Selection input 3

Select output 3 using <arrow key down> Press the ENTER key.

You will then enter the following Input 3 menu. In the default settings, the delay extension is activated under the <Function> menu item. This setting may not be altered.



N Open = Make function in which the contact closes when the switching point is reached.

N Closed = Break function in which the contact opens when the switching point is reached.


Input4

Input1Input2Input 3

Function

Polarity

N Open

NC Contact


Requirement:

The Configuration menu was pre-selected in the

Config menu.

1

2

3

EN

5.3. Input 4 settings

5.3.1Typeofilllevelmonitoring

5.3.2 Fill level monitoring polarity

Input4ispreconfiguredatthefactoryforthe<Filllevel>filllevelmonitoring.Thetypeofthefilllevelsensoristobesetinaccordancewiththesensorthatisactuallyconnected,inordertoensurecorrectfunctioning.Thefollowingsensortypesaresupported

<Agitator> fortheagitator <Mechanics> foramechanicalswitch

<Capacitive> foracapacitivefilllevelsensor <Analog> fortheanalogfilllevelsensor

Ifa<Mechanics>mechanicalswitchisusedasafilllevelsensor,thenthecorrectsignalpolar-ity must be set.

Thesensoractivatesitssignalwhenthelubri-canttanknolongercontainssufficientlubri-cant.Thecontrolthenreportsanerrorandswitchesthelubricationprocedureoffinordertoavoidadditionalsystemdamage.

Setting the polarity for fill level monitoring, Table 1 of 2


1 Selection input 4

Select output 4 using <arrow key down> Press the ENTER key.

You will then enter the following Input 4 menu. In the default settings, the fill level is activated under the <Function> menu item. This setting may not be altered.

Select the <Type> switch type by using <arrow key down>.


You will enter the Fill level switch <Type> menu. Select the type using <arrow keys up/down>.

Input1Input2Input3

Function

Type

Polarity

Input 4


Requirement:


Config menu.

1

2

3

EN

Setting the polarity for fill level monitoring, Table 2 of 2


2 Assign the <Type> switch type and <Polarity> function definition to input 4

You will return to the Function menu. Depending on the function assignment (Step 2), the following are available:

Function Type Polarity

Level SW Agitator Agitator rotations (W1) - Mechanics Mechanical fill level switch NO contact/NC contact Capacitive Capacitive fill level switch - Analog Analog fill level switch -

Select the <Mechanics> switch type by using <arrow key down>. Press the ENTER key.

You will enter the Fill level switch <Type> menu. Select the type using <arrow keys up/down>. Press <arrow key left> to exit the menu You will enter the fill level switch <Type> menu.

3 Select Polarity using <arrow key down>. Press the ENTER key.


N Open = Make function in which the contact closes when the switching point is reached. N Closed = Break function in which the contact opens when the switching point is reached.


AgitatorMechanics

Capacit.

Function

Type

Polarity

Function

TypePolarity

N Open

NC Contact


EN

5.4 Setting the outputs

5.4.1 Valve control polarity

5.4.2 Error output polarity

Thetwooutlets,outlet1andoutlet2,areas-signedatthefactorytothetwochangeovervalves,valve1andvalve2.Thefollowingapplies:Outlet1isassignedtochangeovervalve1<Valve1>formainfeedline1

Outlet2isassignedtochangeovervalve<Valve2>formainfeedline2.Thetypeofthepolarityofthetwochangeovervalves,asNCContactsorasNOContacts,musthoweverbeestablishedbythecustomerforbothoutputs. Thesameappliesfortheerroroutput.Here,too,thedefinitionoftheswitchingfunctionisthecustomer'sresponsibility.

Defining the polarity for system outputs and the error output, Table 1 of 2


1 Selecting output 1 or output 2

Select outputs using <arrow key down> Press the ENTER key; you will then enter the fol-

lowing Output menu Press the ENTER key; you will then enter the fol-

lowing Output 1 menuor:

Select between output 1 and output 2 using <arrow keys up/down>

Press the ENTER key; you will then enter the fol-lowing Function menu

The <Valve> function has already been activated (changeover valve) for output 1 and output 2 in the following Function menu.In the case of output 1, the changeover valve <Valve 1> is intended for outlet 1 for main feed line 1, while for outlet 2 the changeover valve <Valve 2> is intended for main feed line 2.

InputsOutputs

Default

Output 1

Output 2

ErrorOut

Function

Polarity


Requirement:


Config menu.

1

2

3

EN

Defining the polarity for system outputs and the error output, Table 1 of 2


2 Polarity of the changeover valve


You will enter the Polarity menu.The following are available for selection:

N Open = Make function in which the contact closes when the switching point is reached. NC contact = Break function in which the contact opens when the switching point is reached.


3 Polarity of the error output Select error output using <arrow key down> Press the ENTER key; you will then enter the following Error output menu

You can switch the error output function between make function and break function using <arrow keys up/down>.

Choose between make function and break function using <arrow keys up/down> Press the ENTER key. Press <arrow key left> repeatedly. You will return to the Config. menu

Function

Polarity

N Open

NC Contact

Output 1

Output 2

ErrorOut

NC contact

NO-contact


EN

5.5 Setting the pause, run and dwell times

<Pause>standsfortheprogrammedpausetime of the control for one lubrication cycle.

Thepumpdeliversnolubricantduringthistime.

<Runtime>standsfortheprogrammedpumpruntimeforonelubricationcycle.Duringtheruntime,thepressureisbuiltupandthelubri-cantisdispensedtothelubricationpoint.<Dwelltime>Afterreceivingthemonitoringsignal,thepumpruntimeisendedatonceifthedwelltimehasbeensettoactive.Thecontrolunitthengoesintothepre-setdwelltime.Duringthistime,additionallubricantispumpedintothelubricationpoint,thuscaus-ingthepressuretobuildupagain.Attheendofthedwelltime,thepumpgoesintothepauseIfnopressurebuild-upnotificationensuesduringtheruntime,thenthepumpgoesintoerrormodeafterthecompletionoftherun-

time.Otherwise,thepumpswitchesoverintodwell time. If the dwell time is enabled and set

to"0",thenthepumpswitchesoffafterreceiv-ingtheswitchingsignalandentersintotheprogrammedpausetime.Afterthepausetimeexpires,thepumpruntimestartsupagain.Thefollowingdiagramdepictsthedependencybetweenpauseandruntime.


pause runtime

no pressure build-up signal

Pressure switch/-sensor announces the achievement of the changeover pressure

error

dwell timepause

pause

Pause, runtime and dwell time

EN

Pause, run and dwell times, Table 1 of 2


1 Select the <Line1> lubrication line

Select the Settings menu item using <arrow key down>

Press the ENTER key, you will then enter the following menu for lubrication line 1 for the two main feed lines 1 and 2.


In the case of DuoFlex systems, the menu point <Line2> is deactivated

2 Enter the parameters for system times <Time>

The Time parameter menu is already selected.

Press the ENTER key; you will then enter the following Time menu

SystemSettings

InputsLine 1

Time

Valvesp-Switch


Requirement:


2

3

EN

Pause, run and dwell times, Table 2 of 2


3 Setting the pause time, run times (and dwell when p-switch is enabled for lubrication line 1)

If a dwell time has already been selected under the p-switch menu item, then an additional <Dwell> menu item will be displayed.

The <Pause> parameter menu is already selected.

Press the ENTER key; you will then enter the following <Pause> menuor: Select <Run time> or <Dwell time> using <arrow key up/down> Press the ENTER key; you will then enter the selected menu

<Pause> stands for the pump pause time, <Run time> stands for the pump runtime. <Dwell> stands for the pump dwell time. The dwell time begins as soon as the pump has received the signal from the pressure switch during the runtime. The remaining runtime is skipped; pressure starts building up again during the dwell time.

Enter the input value using <arrow keys> Press the ENTER key to confirm the entry. Go to the end of the line using <arrow key right> or <arrow key left> then press the arrow key again to

exit the menu.

Pause


Runtime


Dwell


Pause

RuntimeDwell


EN

5.6 Specifying the system mode half cycle/full cycle

In the case of dual-line centralized lubrication

systems,adistinctionismadebetweentwosystemvariants,betweenhalfcycleandfullcycle.

<Half cycle> Inthecaseofthehalfcycle,thecontrolentersruntime1afterthespecifiedpausetime.Afterruntime1hasexpiredandtheswitchingsignalhasbeenreceived,ade-

pressurizationofthemainfeedline(1or2)thatwasunderpressuretakesplace.Thecon-

trolunitsimultaneouslygoesintothepausetime.Runtime2followsafterdepressurizationandexpirationofthepausetime.Afterexpira-

tionofruntime2andthereceivingoftheswitchingsignal,adepressurizationofthemainfeedline(1or2)thatwasunderpres-suretakesplace.Thecontrolunitsimultane-

ouslygoesintothepausetime. Onecompletelubricationcycle,comprisedoftwohalfcyclesseparatedbyapausetime,isthuscompleted.<Full cycle> Inthecaseofthefullcycle,thecontrolentersruntime1afterthespecified

pausetime.Afterruntime1hasexpiredandtheswitchingsignalhasbeenreceived,ade-

pressurizationofthemainfeedline(1or2)thatwasunderpressuretakesplace.Thechangeovervalvesimultaneouslyswitchesthepreviouslydepressurizedmainfeedlinetopressurebuild-up.Thecontrolunitsimultane-

ouslygoesintoruntime2.Arenewedpressurebuild-upoftheprevious,depressurizedmainfeed line ensues

Afterexpirationofruntime2andthereceivingoftheswitchingsignal,adepressurizationofthemainfeedline(1or2)thatwasunderpressuretakesplace.Thecontrolunitsimulta-

neouslygoesintothepausetime. Onecompletelubricationcycle,comprisedoftwohalfcyclesinsuccession,isthuscompleted.Thespecificationofthesystemmodeinhalfcycleorfullcycletakesplaceinthemenu: < Line 1> => <Cyc. Type> =>

<Half-cyc. / Full cycl.>

Half cycle/full cycle

Half cycle:

Full cycle:

LegendPause:

Runtime (1)

Runtime (2)

EN

Half cycle/full cycle



Select the <Settings> menu item using <arrow key down>


Press the ENTER key; you will then enter the following menu, Parameter adjustment for lubrication line 1


2 Input of the parameters for system times <Cyc.l Type>

The Time parameter menu is selected Select the Cyc. Type menu item using <arrow key down> Press the ENTER key; you will then enter the following Cyc. Type Type Select the system mode half cycle or full cycle using <arrow key up/down>. Press the ENTER key to confirm the selection. Press <arrow key left>. Press <arrow key left>. You will return to the parameter adjustment base menu for lubrication line 1.

SystemSettings

InputsLine 1

TimeValvesp-Switch

Cyc. Type

Delay

Half-cyc.

Full cyc.

Requirement:


2

3

EN

5.7 Activation/deactivation of the delay extension

Themenuitem<ExtDelay>(delayextension)canbeusedtostopthelubricationthroughin-

put3duringthepausetime.Dependingonthepolaritythatissetatinput3,theextensionofthepausetimetakesplacewithclosed<NOcontact>oropened<NCContact>.Theactivedelayextensionsignalhasnoinfluenceonthelubricationprocessduringtheruntime.Intheeventofanactivedelayextensionsignalinthepausetime,theremainingpausetimewillbestoppeduntilthesignalisreleased.Afterwards,thelubricationprocessisresumedwiththere-

mainingpausetime.Afterthepausetimeex-pires,theruntimeisstartedupagain.Thefollowingdiagramdepictsthedelayexten-

sion with half cycle and full cycle.


Delay extension

Half cycle:

Full cycle:

LegendPause:

Delay extension

Runtime (1)

Runtime (2)

Existing delay extension signal >>>>>>>>

Existing delay extension signal >>>>>>>

Existing delay extension signal >>>>>>>>

Note!The duration of the delay extension corresponds to the duration of the existing signal

EN

Delay extension



Select the <Settings> menu item using <arrow key down>




2 Enter the parameters for system times <ExtDelay> (delay extension)

The Time parameter menu is selected Select the <ExtDelay> menu item using <arrow key down> Press the ENTER key; you will then enter the following <ExtDelay> menu with <arrow key up/down>, deactivate <none> or activate delay extension, e.g. <Input3> Press the ENTER key to confirm the selection. Press <arrow key left>. Press <arrow key left>. You will return to the parameter adjustment base menu for lubrication line 1.

SystemSettings

InputsLine 1

TimeValvesp-Switch

Cyc. TypeDelay

None

Input 3


Requirement:


2

3

EN

6. Status display

Displayofthecurrentcontrolunitstatus6.1 Status - Display of current device status

Configuration menu


1 Entry mask/language selection

The German version is active by default (flashing).Press the "up" arrow key to change to the English version.


2 Main menu use <up/down> arrows to select "Status"

You will enter the Status menu.

Press the ENTER key; you will then enter the Status menu

3 Device status menu

In the device status menu, you can view the sta-tuses for:

Lub = runtimes for the selected line Fault = Display of current system faults IO State = Electrical state of inputs and

outputs IO Conn = Connection states of inputs and

outputs Temp = requisition of the ambient

temperature

The currently enabled selection is highlighted by flashing. Data cannot be entered or changed in this display mode.

English

German

Info

Conig Status

IO Conn.

Temp.

Lub

Error

IO State

Thestatusmodeisstartedbyselecting<Status>inthemainmenuandpressingtheENTERkey.Thecontrolunitofferstheoptionofviewingthestateandconnectionstatusofinputsandoutputs,allcurrentlyactiveerrors(forerrortime,see<Info>menu)andtheam-

bienttemperatureofthecontrolunit,aswellasoftrackingthecurrentstatusofthelubrica-

tionprocess.Thedataarerecordeddataandtherefore cannot be edited.

Selectioninstatusmodeisperformedbybrielypressingoneofthe keys.

1

2

3

6.Statusdisplay

EN

Runtimes and pause times, Table 1 of 5


1 Runtimes of lubrication process

The <Lub> menu item is already enabled (flashing).


You will then enter the following menu for <Lub>. Line 1 is already selected

Press the ENTER key. You will enter the selected menu <Line 1>.

2 View the active time of the lubrication process

The Lubtime menu item is already enabled.

Press the ENTER key for the current display of the runtime or pause time or delay time still remaining

Details about the specification of the runtime,pause time and delay time can be found in Chapter 2.3.4.

Press <arrow key left> to exit the menu You will return to the previous menu.

6.2 Lub - Runtimes of the lubrication process

6.3 Extracting the activated inputs

Prerequisite.

The device status menu <Status> was pre-selected in the main menu (Chapter 2.1.1).

The DuoFlex lubrication system is activated In the System sub-menu (see Chapter 2.3). The lubrication process is carried out in sev-eral phases, in pump runtime, delay time as needed, pause time and immediately (<DK>). The remaining run times of these phases are displayed for the lubrication line. In the <Status> menu item, sub-menu <Line1>, sub-menu <Lub time>, you can view the currently remaining runtime or the cur-rently remaining pause time of the lubricant process. In the <Inputs> menu item, you can view the inputs assigned to the selected lubrication line.

Lub

Error

IO State

Line 1

Lubtime

Inputs

Pause

ØØØØØh

ØØm ØØs

Runtime

ØØØØØh

ØØm ØØs

or

Display menu

1

2

3Lub

Error

IO State

6.Statusdisplay

EN



3 Reading the inputs (viewing active lubrication or pause time) <Inputs>

Select the <Inputs> menu item using <arrow key down> Press the ENTER key.

You will enter the Inputs sub-menu.

Select <Input 1 (2 or 3 or 4)> using <arrow key up/down> Press the ENTER key. You will enter the selected menu <Input 1> (2 or 3 or 4).

3.1 Monitoring the pressure sensor (digital or analog)

The specification of input 1 and input 2 as <p-switch> (pressure sensor) was already carried out at the factory. The selection of the pressure sensor type, analog or digital, along with its polarity takes place in the menu <Config>, <Inputs>, <Input 1> and <Input 2>. See Chapter 2.3.2 If the selected input (Input 1 or Input 2) configured as a digital pressure sensor type, then the digital value read will be depicted.

If the selected input (Input 1 or Input 2) configured as an analog pressure sensor type, then the analog value read will be depicted.

Press <arrow key left> to exit the menu You will return to the previous menu <Status>

Lubtime

Inputs

Input4

Input 1

Input2Input3

Digital

p-Switch

Ø

Analog

p-Switch

1016

or

6.Statusdisplay

EN



3.2 Read the number of machine contacts of the monitoring system <MCCount>

In the case of DuoFlex systems, this menu item is deactivated <none>

3.3 Fill level sensor fill level control of the existing lubricant

Details on the configuration of an input as fill level sensor can be found in Chapter 2.3.2

Select the <Inputs> menu item using <arrow key down> use <arrow key up/down> to select the input with the fill level sensor, e.g. <Input 4>

Press the ENTER key; you will then enter the following menu for the selected input

In the case of an agitator, the expected and the already counted revolutions will be displayed:

EX = Expected rotations RX = Rotations counted thus far.

MC Count

EX Ø

RX Ø

Rotation

EX Ø

RX Ø

6.Statusdisplay

EN



3.3 If the input was assigned as a capacitive sensor or mechanical switch, the status of the output signal is

displayed: 0= Inactive signal 1 = Active signal

If the input was assigned as an analog switch, the status of the output signal is displayed in %: 0 -100% = Current fill level

Press <arrow key left> to exit the menu You will return to the previous menu.

3.4 Display of the lubrication pulses, starting from an external pushbutton <DK>

With an external pushbutton, it can be seen whether or not the pressure switch is active. Press <arrow key left> to exit the menu You will return to the previous menu <Status>.

3.5 Status display for delay extension input

If the input is assigned as a delay extension, then the status of the input signal is displayed: 0 = Inactive delay extension 1 = Active delay extension

Level SW

Ø

Fill level

~ Ø%

External DK

Ø

ExtDelay

Ø

6.Statusdisplay

EN



3.6 Display of stop input (error input) v

If the input was assigned as stop input, then the lubrication line is stopped as soon as the signal of the error input responds. The following is displayed:

0 = Inactive no fault notification (error signal) at the input 1 = Active fault notification (error signal) at the input

ExtStop

Ø

6.Statusdisplay

EN

Read fault times


1 Details of a system error

Use <arrow key down> to select the Errors menu item, the details of which are displayed

Press the ENTER key. You will enter the selected menu for the details

of the selected error

Possible system errors and their remedies are listed in the chapter "Errors, causes, and remedies".

You will return to the previous menu.

Clearing errors

Press the key to clear all errors and restart the lubrication process on all main lines.

Press the key Press <arrow key left> to exit the menu

6.4 Display active errors

Lub

Fault

IO State

None

The device status menu <Status> was pre-selected in the main menu (Chapter 2.4).

Thestatusmenuhasasub-menu<Faults>fordisplayingallrecognizedsystemerrorsThecontrol causes the red LED to flash as soon as

asystemerrorisdetected.Intheeventofgraveerrors,thelubricationlineisswitchedoffinordertoavoidadditionaldamage. Presenterrorsaredisplayedasfollows:Selectthedevicestatusmenu<Status>inthemainmenu,followedbytheerrormenu<Errors>intheStatusmenu.Uponconfirmation,thesourcesofalldetectedfaultsaredisplayed.The details of the error to be changed are dis-played after the error has been selected and the selection has been confirmed.

1

2

3

The possible errors are listed in the chapter Errors, causes, and remedies.

Lub

Error

IO State

6.Statusdisplay

EN

Electrical state of inputs and outputs


1 States of inputs and outputs

Select the <IO State> menu item using <arrow key down>

Press the ENTER key. You will enter the selected menu for the electri-

cal state of inputs and outputs

2 IO state of inputs and outputs

The menu displays the electrical statuses of control inputs (max.4) and control outputs (max. 2 + Motor)

Connection representing an output

Connection representing an input

1 2 3 4 1 2 = Numbers of pump connections M = Motor connection

0 = At the connection there is no voltage (or a negative voltage) present1 = A positive voltage is present at the connection Press <arrow key left> to exit the menu You will return to the previous menu.

IO Conn.

Temp

6.5 IO State - Read electrical states of inputs and outputs

Lub

Fault

IO State

Prerequisite:

The device status menu <Status> was pre-selected in the main menu, and <IO Stat.> was selected in the device status menu, and the selection was confirmed.

The DuoFlex lubrication system is activated in the System sub-menu (see Chapter 2.3.1). Electrical statuses of inputs and outputs can be viewed.

represents an output and represents an input. The second line contains the number of the output or input.

The electrical state of an output or input is displayed as 0 if there is no voltage at the output or input; it is 1 if there is sufficient measurable voltage.

1 2 3 4 M 1 20 0 0 0 0 0 0

1

2

3Lub

Error

IO State

6.Statusdisplay

EN

Electrical state of inputs and outputs


1 Connection statuses of inputs and outputs

Select the IO Conn. menu item using <arrow key down>

Press the ENTER key. You will enter the selected menu for the electrical

connection of inputs and outputs.

2 IO connection of inputs and outputs

The menu displays the programmed control inputs (max.4) and control outputs (max. 2 + Motor)

Connection representing an output

Connection representing an input

1 2 3 4 1 2 = Numbers of pump connections M = Motor connection

= Current connection

=Current interruption

Press <arrow key left> to exit the menu You will return to the previous menu <Status>.

6.6 IO Conn. - read connection states of inputs and outputs

Lub

Fault

IO StateRequirement: The device status menu <Status> was pre-

selected in the main menu.

Connection states of inputs and outputs can be viewed.

represents an output and represents an input.

The second line contains the number of the output or input.

stands for a continuous connection and stands for an interruption.

IO Conn.

Temp

1 2 3 4 M 1 2

1

2

3IO State

IO Conn.

Temp

6.Statusdisplay

EN

Ambient temperature of control unit


1 Read ambient temperature

Select the Temp menu item using <arrow key down>

Press the ENTER key. You will enter the selected menu for the ambi-

ent temperature on the control unit.

2 Temperature display

The menu shows the ambient temperature of the control unit

Press <arrow key left> to exit the menu You will return to the previous menu <Status>.

6.7 Read ambient temperature on the control unit

Lub

Fault

IO StatePrerequisite:

The device status menu <Status> was pre-selected in the main menu

The control unit is equipped with a tempera-ture sensor for measuring the ambient tem-perature (pump). If the temperature is too high or too low, all lubrication processes will be halted and resumed only once the temper-ature has normalized. The limit for low temperature is below -25°C, and the limit for high temperature is over +70°C. The limits can only be modified by the manufacturer!

IO Conn.

Temp

Temp

Ø Ø C°

1

2

3IO State

IO Conn.

Temp

6.Statusdisplay

EN

7. Basic settings

7.1 Basic initialization of control unit

Basic initialization


1 Basic initialization

Select the <Default> menu item using <arrow key down> Press the ENTER key. You will then enter the following Basic initialization menu.

2 Basic initialization menu

The basic initialization menu is used to restore the default factory settings. Select between cancel and save using <arrow keys up/down>. Press the ENTER key. Press <arrow key left> to exit the menu You will return to the Config. menu.

Cancel

Save

System

SettingsInputs

OutputsDefault

Reset

7.Basicsettings

Toloadthefactorysettings,<Default>isselectedandconfirmedintheConfigurationmenu.Aftertheconfirmation,aqueryisissuedastowhetherthechangesshouldbesavedornot.Whatismeantisthesavingoffactoryinitializationdata.Afterthesavingprocedure,allprevioussettingmodificationsarelostandthedeviceishasthesettingswithwhichitwasoriginallydelivered

1

2

3

Outputs

Default Reset

EN

7.2 Control unit reset function

Control unit reset function



Select the <Reset> menu item using <arrow key down> Press the ENTER key. You will enter the following Reset menu.

2 Reset menu

The lubrication system is cleared and set in reset status in the Reset menu. Select between cancel and save using <arrow keys up/down>. Press the ENTER key. Press <arrow key left> to exit the menu You will return to the previous menu.

Cancel

Save

System

SettingsInputsOutputsDefault

Reset

7.Basicsettings

TheResetfunctioncanbeusedtoclearthesettingsofthecontrolunitandreturntheunittoresetstatus.Inthisstatus,allofthedevicesofthesamesystemtypehaveidenticalsettings.

1

2

3

Outputs

Default Reset

EN

7.3 Resetting the user password for the control unit for coniguration changes

Password change



Select the <New Pwd> menu item using <arrow key down> Press the ENTER key. You will enter the following password editing window.

2 Enter new password A new password can be entered in the password editing window. The old user password is accessed

and displayed when the window is opened. The configuration menu for settings changes can be opened with this password.

Enter the input value using <arrow keys up/down> Press the ENTER key to confirm the entry.

or Use <arrow keys left/right> to move the cursor position to the desired location. Press the ENTER key to confirm the entry. Enter the new value using <arrow keys up/down> Press the ENTER key. You will return to the Config. menu.

Reset

ØØØØØØØØ

System

SettingsInputsOutputs

Default

ResetDefault

Reset

New Pwd

Theuserpasswordisfactorypre-setto"0"decimalplaces.Onlynumeralsbetween0and9arepermitted.Themenuitem<NewPwd>isselectedandconfirmedintheconfigurationmenu<Config.>forthepurposeofchangingtheuserpasswordforconfigurationchanges.Afterwards,awindowforenteringthenewpasswordopens.Thecurrentlyflashingcursorpositionischangedwiththekeysup/down.Thecursorpositioncanbechangedwiththerightandleftkeys.

1

2

3Default

Reset

New Pwd

previous password

00000000

7.Basicsettings

EN

8.1 Control cubicle

8. Electrical connections/wiring


Mounting diagram, control cubicle, version 24 VDC, 230 VAC, 400 VAC

300

300

2

3

1

ca. 3

3021

0ca

. 220

ca. 340

Schmierung starten

Start lubrication

FehlerFault

7-D26-H16-S1

6-H2

6-Q1

X 2

X 3

X 1

1 2 3

4 5 6

PEPE

5 6

1 2 3

4

1 2 PE 3 4 PE PE

24

9 10 1112

2322212019181716151413

1 2 3 4 5 6 7 8

242322212019181716151413

9 10 11121 2 3 4 5 6 7 8

PE PE

8-K

4

8-K1M6-Q2

6-F

1

6-Q1

X 2

X 1

X 3

24

9 10 1112

2322212019181716151413

1 2 3 4

5 6 7 8

PE PE

5 6 7 8

1 2 3 4

1 2 3 4 5 6 7 8

242322212019181716151413

9 10 11121 2 3 4 5 6 7 8

L1 L2 L3 N PE U V WPE PE

PE PE

6-K

2

8-K

4

8-K1M

6-Q2

6-T1 6-F

16

-F2

6-Q1

X 2

X 1

X 3

24

9 10 1112

2322212019181716151413

1 2 3 4

5 6 7 8

PE PE

5 6 7 8

1 2 3 4

1 2 3 4 5 6 7 8

242322212019181716151413

9 10 11121 2 3 4 5 6 7 8

L1 N PE 1 2 PE PE

PE PE

6-K

2

8-K

4

8-K1M

6-Q2

6-T1 6-F

16

-F2

6-Q1

24 VDC 230 VAC 400 VAC

Outlet 1 (LC502 control)Outlet 2 (LC502 control)Fault outputInlet 1 (LC502 control)Inlet 2 (LC502 control)Inlet 3 (LC502 control)Inlet 4 (LC502 control)Pump supply to pump motorPower supply to control cabinet

X2

X1

X3

EN

8.2.1 Power supply 24 VDC

8.2.2 Power supply 230 VAC 8.2.3 Power supply 400 VAC8.2 Terminal strip X1 power supply


400 VAC 24 VDC

Assignment of the terminal strip X1 with 400 VAC

L1 Power supply (L1)L2 Power supply (L2)L3 Power supply (L3)N Power supply (N)PE protective (earth) conductorL1 Motor (L1)L2 Motor (L2)L3 Motor (L3)PE protective (earth) conductorPE protective (earth) conductor

Assignment of the terminal strip X1 with 24 VDC

1 Power supply (+)2 Power supply (-)PE protective (earth) conductor3 Motor (+)4 Motor (-)PE protective (earth) conductorPE protective (earth) conductor

230 VAC

Assignment of the terminal strip X1 with 230 VAC

L1 Power supply (L1)N Power supply (N)PE protective (earth) conductorL1 Motor (L1)N Motor (N)PE protective (earth) conductorPE protective (earth) conductor

Cabletype Cabletype

Term

inal

blo

ck: X

1

Aim

1

Terminal-No. Bridge

BMK

Connector

Position

Feed in Power supply

3G2,5 3G2,5

1 2 grge

1 2 grge

Fee

d in

Fee

d in

Fee

d in

Mot

or M

otor

Mot

or

Cus

tom

er C

usto

mer

Cus

tom

er 6

-M1

6-M

1 6

-M1

+ - PE

1 2 PE 3 4 PE PE

PE+ -

Cabletype CabletypeTe

rmin

al b

lock

: X1

Aim

1

Terminal-No. Bridge

BMK

Connector

Position


3G2,5 3G1,5

sw bl grge

1 2 grge

Fee

d in

Fee

d in

Fee

d in

Mot

or M

otor

Mot

or

Cus

tom

er C

usto

mer

Cus

tom

er 6

-M1

6-M

1 6

-M1

PE

L1 N PE 1 2 PE PE

L1 N PE L1 N

Cabletype Cabletype

Term

inal

blo

ck: X

1

Aim

1

Terminal-No. Bridge

BMK

Connector

Position


5G2,5 4G1,5

sw br sw bl grge

1 2 3 grge

fee

d in

fee

d in

fee

d in

fee

d in

fee

d in

Mot

or M

otor

Mot

or M

otor

Cus

tom

er C

usto

mer

Cus

tom

er C

usto

mer

Kun

de 6

-M1

6-M

1 6

-M1

6-M

1

U V W PE

L1 L2 L3 N PE U V W PE PE

L1 L2 L3 N PE

EN

8.3

Te

rmin

al strip

X2 a

ssignm

ent o

f the in

puts w

ith a

nalo

g p

ressu

re se

nso

r


Termin

al strip

X2, In

puts w

ith a

nalo

g p

ressu

re se

nso

r

associated terminal diagram

- see Chapter 8.3.1

Cabletype Cabletype

Terminal block: X2

Aim 1

Terminal-N

o.

Bridge

BMK

Connector

Position

123456789

101112PEPE

131415161718192021222324PEPE

Pressure sensor, line 1 Pressure sensor, line 2 D

elay extension Fill level

3X0,75 3X0,75 2X0,75 3X0,75

12

3

12

3

1kΩ1kΩ

12

+ Delay extension - Delay extension

Customer

Customer

+

-

+24V Fill leve

Signal Fill levelOV Fill level

12

3

Fill leve1

23

Fill level Fill level

1

34

1

34

Pressure, line 1

Pressure, line 1 Pressure, line 1

Pressure, line 2

Pressure, line 2 Pressure, line 2

Pressure sensor 1

Pressure sensor 1 Pressure sensor 1

Pressure sensor 2

Pressure sensor 2 Pressure sensor 2

EN

8.3.1 Terminal diagram X2 assignment of the inputs with analog pressure sensor


Terminal diagram

Terminal strip X2 (24V)

Input No. Function 2-wire switch

3-wire switch

Analog sensor

Input 1 1 not connected

2 Pressure sensor 1 (+24V) X

3 not connected

13 Pressure sensor 1 (signal) X | *)

14 Pressure sensor 1 (0V) X | *)

15 not connected


5 Pressure sensor 2 (+24V) X

6 not connected

16 Pressure sensor (signal) X | *)

17 Pressure sensor 2 (0V) X | *)

18 not connected

Input 3 7 Delay extension (+) X

8 not connected

9 Delay extension (-) X

19 not connected

20 not connected

21 not connected


11 Fill level (+24V) X

12 not connected

22 Fill level (Signal) X

23 Fill level (0V) X

24 not connected

2-wire switch • Switches, buttons, etc. • Pressure switches • Differential pressure switch (requires 2 inputs) • mech. ill level switch (FF and FB pumps) 3-wire switch • ultrasonic ill level switch • W2 ill level control (capacitive proximity switch) Analog sensor • Pressure sensor • analog ill level sensor *) When analog sensors are used, a BES6 link plug (equipped with a resistance of 1.0 kΩ, 0.5 W) must be installed between "Signal (-)" and "power supply (-)" for measuring range adjustment.

EN

8.3

.2 Te

rmin

al strip

X2 a

ssignm

ent o

f the in

puts w

ith D

DS

50/1


Termin

al strip

X2, in

puts a

nd o

utp

uts w

ith d

iffere

ntia

l pre

ssure

switch

DD

S50/1

associated terminal diagram

- see Chapter 8.3.3

Cabletype Cabletype

Terminal block: X2

Aim 1

Terminal-N

o.

Bridge

BMK

Connector

Position

Differential-pressure sw

itch 5G0,75

123456789

101112PEPE

131415161718192021222324PEPE

Delay extension

Fill level

12

2X0,75 3X0,75

grge3

4

12

Pressure, line 1

Pressure, line 1

+ Delay extension

- Delay extension

+24V Fill level

Signal Fill levelOV Fill level

Differential-pre. sw.

1

23

4

Pressure, line 2

Pressure, line 2 Customer

Customer

12

3

F Fill level1

23

PE

+

-

Fill level Fill level

Differential-pre. switch Differential-pre. switch Differential-pre. switch

Differential-pre. switch

Differential-pre. switch

EN

8.3.3 Terminal diagram X2 assignment of the inputs with DDS50/1


Terminal diagram

Terminal strip X2 (400V, 230V, 24V)

Input No. Function 2-wire switch

3-wire switch

Analog sensor

Input 1 1 Differential pressure switch (1) X

2 not connected

3 Differential pressure switch (2) X

13 not connected

14 not connected

15 not connected

Input 2 4 Differential pressure switch (3) X

5 not connected

6 Differential pressure switch (4) X

16 not connected

17 not connected

18 not connected

Input 3 7 Delay extension (+) X

8 not connected

9 Delay extension (-) X

19 not connected

20 not connected

21 not connected


11 Fill level (+24V) X

12 not connected

22 Fill level (Signal) X

23 Fill level (0V) X

24 not connected

2-wire switch • Switches, buttons, etc. • Pressure switches • Differential pressure switch (requires 2 inputs) • mech. ill level switch (FF and FB pumps) 3-wire switch • ultrasonic ill level switch • W2 ill level control (capacitive proximity switch) Analog sensor • Pressure sensor • analog ill level sensor *) When analog sensors are used, a BES6 link plug (equipped with a resistance of 1.0 kΩ, 0.5 W) must be installed between "Signal (-)" and "power supply (-)" for measuring range adjustment.

EN

8.4.1 Outputs 24 VDC 8.4.2 Outputs 230/400 VAC

8.4 Terminal strip X3, outputs

Version 24 VDC

ThefaultsignalcanbeprogrammedeitherasNCContact(NC)orasNOContact(NO).NC= Signalinterruptionintheeventof a fault

NO=Signaltransmissionintheevent of a fault


X3, 24 VDC

Assignment of the terminal strip X3 with 24 VDC

1 Output 1 (+)2 Output 2 (+)3 Fault notification (+)4 Output 1 (-)5 Output 2 (-)6 Fault notification (-)PE protective (earth) conductorPE protective (earth) conductor

X3, 230 VAC/400 VAC

Assignment of the terminal strip X3 with 230/400 VAC

1 Output 1 (+)2 Output 2 (+)3 Fault signal (Com)4 not connected5 Output 1 (-)6 Output 2 (-)7 Fault signal (NC) 8 Fault signal (NO) PE protective (earth) conductorPE protective (earth) conductor

Cabletype Cabletype

Term

inal

blo

ck: X

3

Aim

1

Terminal-No. Bridge

BMK

Connector

Position

Valve 1 Valve 2

3G1 3G1

1 2 3 PE PE 4 5 6 PE PE

Fault signal 2X0,75

1 1 PE PE 2 2

1 2

1 2

grge

grge

1 2

Cus

tom

er

Cus

tom

er

Fau

lt si

gnal

Fau

lt si

gnal

+ -

Val

ve, l

ine

1 V

alve

, lin

e 2

Val

ve, l

ine

1 V

alve

, lin

e 2

VVa

lve,

line

1 V

alve

, lin

e 2

Cabletype Cabletype

Term

inal

blo

ck: X

3

Aim

1

Terminal-No. Bridge

BMK

Anschluss

Ort

Valve 1 Valve 2

3G1 3G1

1 2 3 4 PE PE 5 6 7 8 PE PE

Fault signal NC Fault signal NO

2X0,75 2X0,75

1 1 PE PE 2 2

1 2

1 2

grge

grge

1

1

2

2

Cus

tom

er

Cus

tom

er C

usto

mer

Fau

lt si

gnal

Fau

lt si

gnal

Fau

lt si

gnal

Val

ve, l

ine

1 V

alve

, lin

e 2

Val

ve, l

ine

1 V

alve

, lin

e 2

Val

ve, l

ine

1 V

alve

, lin

e 2

EN

9. Operational and pump faults

9.1 Operational malfunctions

9.1.1 General information

The operator/operating personnel must perform visual ill level control of the lubricant reservoir at regular intervals. The control intervals depend on the amount of lubri-cant required and the pump's runtime. The operator/operating personnel must therefore determine the intervals on their own based on the speciic conditions of usage.

If the reservoir has been pumped empty, the entire system must be bled after reilling (see "Assembly" chapter).

9.1.2 System errors

The LC502 control unit is able to detect a

rangeofdifferentsystemfaults.ThecontrolunitactivatestheredLEDassoonasanerrorisdetected.Anactivefaultisviewedasfollows:Selectthedevicestatusmenu<Status>inthemainmenu,followedbytheerrormenu<Errors>intheStatusmenu.Uponconfirma-

tion,thesourcesofalldetectedfaultsaredis-

9.3 Deletefaultnotiication

All error notiications can be acknowledged and cleared using the key; the lubrication process restarts. This can be performed by an external pressure switch (DK, see Chapter 2.3.2) if desired.

Warning!

Determine and remedy the cause of faults before deleting fault notiications. The user is liable for damages result-ing from operating the machine without lubrication.

playedinplaintext.AfaultcanbeselectedintheErrormenutoviewitsdetails.

9.2 Display faults

Select the error display menu.

Step Key Display

1

2

3

English

German

Info

ConigStatus

Lub

Fault

IO State


EN

Fault types

Fault type Definition Display Example of fault Correction (control unit)

Mal-function

A fault has occurred that affects the proper functioning of the lubrication system.

The lubrication points may

not be supplied with adequate

lubrication because a

malfunction has affected the

proper functioning of the lubri-

cation system.

Malfunctions must always be

remedied immediately.

- LED flashes

Fill level in the reservoir sinks to the level of the pre-warning sensor (only on systems equipped and configured with this functionality).

No pressure build-up during pump runtime

No pressure release during pause time

1. Extend pump runtime or enter delay time2. Inspect connections for connection3. If no changeover signal is Pressure sensor: o Check pressure sensor connection o Check pressure sensor and replace if necessary4. Changeover valve does not switch: o Check connection of changeover valve o Check changeover valve and replace if necessary

9.4 Fault types

The control unit issues a malfunction notiica-tion with each fault that occurs (see following table).


EN

9.5 Errornotiication

1

2

3Lub

Errors

IO State

Displayed error notifications

Fault notification Category Possible cause Rectification

Current error Malfunction o The measured motor current has gone below the limit.

• Remove agitator jamming • Check lubricant delivery

Tank gauge error(error in fill level indicator)

Malfunctiono The fill level sensor of the agitator (W1) does not measure pulses after more than 25 seconds, although the pump motor is on. o The analog, capacitive, or mechanical fill level sensor/switch indicates an empty tank even though the lubricant reservoir still contains suffi-cient lubricant.o Connection interrupted

• Check pump fill level• Inspect the mechanical fill level switch (W1) for proper function and replace if necessary

• Inspect the connection of the fill level switch and replace the outlet or fill level switch if necessary

• Inspect the connection of the fill level switch

Temperature error Malfunction o This error is reported if the temperature rises above or falls below the maximum or minimum operating temperature, respectively.

• Change the ambient conditions so that a permissible operating temperature is achieved for the control unit/pump(temperature range -25 - 70°C)

Output error Malfunction This error is reported if a short circuit or line break is detected at the output. This is a connec-tion error in both cases. To display the specifics of the error, first select the affected output.

• Inspect the affected output connections for short circuit or line break and rewire if necessary.


EN

Displayed error notifications

Fault notification Category Possible cause Rectification

Input error

- Connection error

- Pressure error

Malfunction Different signal sources can be connected to a single input. Errors that are detected on an input can therefore have various causes. A list of possible input errors follows:

o Connection errors are reported if the signal source configured for the input must conduct closed-circuit current but the measured cur-rent is below the expected minimum value. The problem may lie in a cycle switch or an analog or capacitive fill level monitoring sensor.

o Dual-line centralized lubrication systems use pressure sensors to monitor the lubrication process. The pressure sensors must report pressure build-up or pressure reduction wit-hin a specified time. If the expected signal is not received within expected time, a pressure error on the affected input is reported.

• Inspect electrical lines and connections of the affected input and replace if necessary

• Inspect fill level switch of the affected input and replace if necessary

• Use a pressure gauge to inspect pressure build-up; if the changeover pressure is not present:

- Inspect pump feeding and replace pump element if necessary - Inspect changeover valve/connections of changeover valve and

replace if necessary- Inspect dual-line distributors for proper function and replace

any defective single-line distributor- Inspect main line for leaks, replace if necessary

• Use a pressure gauge to inspect pressure build-up; if the changeover pressure is present:

- Inspect connections of the pressure sensors and replace cable harness if necessary

- Inspect pressure sensors and replace if necessary • If using an analog pressure sensors, inspect the value range

of the changeover point <p-Active> This value must be in the range of the pressure sensor (20 - 1003).


EN

10. LC502 menu displays

ThefollowingmenudisplaysarebasedonthefullprogrammingoptionsoftheLC502controlunit. The list therefore contains the menus for

ProFlex,MonoFlex,andDuoFlex.

Menu displays, Table 1 of 6

English German Description

English - English language selection

- German German language selection

Info Info Device information menu

Config Konfig Configuration menu

Status Status Device status menu

Service Service Menu reserved for SKF, used for locking important settings

Serial Serie Nr Menu selection for the serial number

Firmware Firmware Menu selection for identifying the program on the control unit

Sys time Sys Zeit Total runtime of the control unit

Mot time Mot Zeit Total runtime of the motor

Err time Störzeit Total time that the current error has been present If there is currently no error state, the display shows the sum time of all errors detected thus far

View Anzeigen Menu selection for configuration view Changes cannot be made. Password is not required.

Edit Ändern Menu selection for editing the configuration


EN



Password Passwort Password entry

System System Menu selection for viewing/editing the mode of operation

Settings Einstel. Menu selection for configuring parameters

Inputs Eingänge Menu selection for configuring inputs

Outputs Ausgänge Menu selection for configuring outputs

Default Grundini Menu selection for restoring default settings

Reset Reset Menu selection for resetting (clearing) the device

New Pwd Neue Pwd Menu selection for changing the user password

ProFlex ProFlex Menu selection for progressive lubrication

MonoFlex MonoFlex Menu selection for single-line lubrication

DuoFlex DuoFlex Menu selection for dual-line lubrication

Line 1/2 Strang 1/2 Lubrication line

Time Zeit Menu selection for configuring lubrication times

Valves Ventile Menu selection for valve assignments

Trials Wiederho Repeat attempts in block mode

p-switch p-Schalt Pressure sensor assignment menu

p-Diff p-Diff Differential pressure on dual-line systems

Cyc-type Zyk. Typ Cycle type (half/full cycle) for dual-line lubrication

Delayer Verzöger Delay extension input (function selection and assignment for the line whose pause time will be halted)


EN



ExtStop Stopeing Error input (function selection and assignment for the line that will be stopped in the event of an error)

MCNumber MCZyklen MC (machine contact input) (function selection and assignment for the line that will be controlled)

Cycles Zyklen Number of cycle inputs that are monitored.

Pause Pause Pause time

Runtime Runtime Pump runtime for the current line

Pause 2 Pause 2 Pause time in block mode (if cycles are absent and a new attempt is started until they are received)

Dwell Nachlauf Delay time in block mode and on single-line and dual-line systems. This is also displayed for enabling/disabling the delay time.

Release Entlast. Selection for pressure relief. The input to be selected afterwards is used for pressure relief.

Build-up Aufbau Selection for pressure build-up. The input to be selected afterwards is used for pressure build-up.

Valve 1/2 Ventil 1/2 Valve 1/2 on a dual-line system

Output 1/2 Ausgang 1/2 Output port 1 and 2

Input 1 - 4 Eingang 1 - 4

Input port 1 to 4

None Kein This is selected if no other selection has been made

p-swit 1/2 p-sch 1/2 Pressure sensor for line 1/2 in dual-line systems

Disabled Inaktiv The selection in the previous menu window is not enabled

Enabled Aktiv The selection in the previous menu window is enabled

Half Halb Cycle model in dual-line systems (half lubrication cycle)

Full Voll Cycle model in dual-line systems (full lubrication cycle)


EN



MCCount1 to MCCount4

MCZähl. 1 bis MCZähl. 4 Selection of MC control input for the affected line

Mon+Stop Mon+Stop Runtime limitation based on agitator rotations, with monitoring by cycle switch. An error is reported in the event of missing cycles.

Monitor Monitor Cycle switches that are monitored during pump runtime. A report is generated if cycles are missing at the end of the runtime and (if applicable) block mode.

Imm. Stop (immediate stop)

Sof. Stop (Sofort Stopp) Lubrication is stopped as soon as the expected cycles are received on the input. No report is gener-ated if cycles are missing on other inputs. This function is also used for the agitator.

Col. Stopp(collective stop)

War. Stopp(Warten und stopp)

An input with this setting monitors other inputs. Lubrication is stopped as soon as the last expected cycle is received on the input and on all other inputs. The input with this setting waits for the last missing cycle on other inputs before it stops lubrication. A report is generated if cycles are missing at the end of the runtime and (if applicable) block mode.

Function Funktion Selection for configuring the function of inputs and outputs

Type Typ Signal type of an input or output (analog/digital)

Polarity Polung Signal polarity: This is how it is defined whether the respective input or output, respectively, func-tions as NO Contact or NC Contact.

Limits Grenzw. Limit values for analog signals

CycCount Zyk Zähl Function of an input as cycle switch

MCCount MC Zähl. Function of an input as machine contact

Level SW Füllhöhe Function of an input as fill level monitoring sensor. This is also used to show errors from the fill level monitoring sensor.

p-switch p-Schalt Function of an input as pressure sensor


EN



ExternDK ExternDK Function of an input as DK input

ExtDelay Pausever Function of an input as delay extension input

ExtStop Stopeing Function of an input as stopper input

Analogue Analog Analog input or output

Digital Digital Digital input or output

N Closed(normally closed)

Öffner Signal polarity of an input or output, respectively, as NC Contact, the signal carries a voltage in non-active status

N Open(normally open)

Schließ.er Signal polarity of an input or output, respectively, as NO Contact, the signal carries a voltage in active status

p-Active p-Aktiv Analog active value of a pressure sensor at an input

ErrorOut Störausg Error output signal. This is activated if an error is present.

Valve SW Ventil Function of an output as valve control signal

Cancel Abbruch Menu selection for canceling or ignoring the selected operation

Save Speiche. Menu selection for saving changes to the configuration

Lub Lub Menu selection for displaying the current status of the lubrication process

Errors Fehler Menu selection for displaying current errors


EN



IO State IO Zust. Menu selection for displaying the electrical state of inputs and outputs.

IO Conn. IO Verb. Menu selection for displaying the connection state of inputs and outputs.

Temp. Temp. Menu selection for displaying the current system temperature or temperature errors

Lubtime Lubzeit Menu selection for displaying the current status and remaining time of the lubrication process

Rotation Drehung Rotations of the agitator

No Error Kein Error display when no error has been detected

Current Strom Error display for a motor current error

Pressure Druck This is used to display pressure errors.

Represents an input

Represents an output

Represents an open connection

Represents a closed connection

ResetPwd ResetPwd Menu selection for editing the user password

Unlocked Stellbar Menu selection for enabling a mode of operation or inputs and outputs

Locked Gesperrt Menu selection for blocking a mode of operation or inputs and outputs

Delayer Verzöger Delay extension input (function selection and assignment for the line whose pause time will be halted)


EN

11. Technical data of the LC502 control unit

11. Technical data of the LC502 control unit

11.1 Basic setting of the LC 502

Pause time: 00008 h, 00 m, 00 s Pump runtime: 00000h, 04m, 00s Dwell time: 0000 h, 00 m, 05 s

correspondstoapausetimeof8hours correspondstoapumpruntimeof4minutes correspondstoadwelltimeof5secondsBasicsettingoftheinputsandoutputs Pump:


forFF/FBmulti-linepump <Type>=><Mechanics>(Filllevelswitchforminimumdisplay) <Polarity>=><NCcontact>(Default) forFKpump <Type>=>>capacit.>FilllevelswitchforMinLubrication line 1:

<Input 1> =><Function>=><p-switch>=> <Type>=><Digital>=><Polarity>=><NOcontact>(DDS50/1,mainfeedline1)<Input 2> => <Function> => <p-switch> => <Type> => <Digital> => <Polarity> => <NO contact> (DDS50/1, main feed line 2)

<Input 3> =><Function>=><ExtDelay>=><Polarity>=><NCcontact><Output 1- =><Valve>=><Polarity>=><NOcontact>(changeovervalve,mainfeedline1) <Output 2> =><Valve>=><Polarity>=><NOcontact>(changeovervalve,mainfeedline2)

951-180-007-EN

SKF Lubrication Systems Germany GmbH 2. Industriestrasse 4 ·68766 Hockenheim · Germany Tel. +49 (0)62 05 27-0 · Fax +49 (0)62 05 27-101 www.skf.com/lubrication

SKF Lubrication Systems Germany GmbH Motzener Strasse 35/37 ·12277 Berlin · Germany PO Box 970444 · 12704 Berlin · Germany Tel. +49 (0)30 72002-0 · Fax +49 (0)30 72002-111 www.skf.com/lubrication

ThecontentsofthispublicationarethecopyrightofthepublisherandmaynotbereproducedinwholeorinpartwithoutpermissionofSKFLubricationSystemsGermanyGmbH.Everycarehasbeentakentoensuretheaccuracyoftheinformationcontainedinthispublication.However,noliabilitycanbeacceptedforanylossordamagewhetherdirect,indirectorconse-

quential,arisingoutofuseoftheinformationcontainedherein. Ifthecomponentissuppliedtogetherwiththeapplicablecomponentlifecyclemanual, thatmanualmustbereadandfollowed.Notalllubricantscanbefedusingcentralizedlubri-cationsystems.SKFcan,onrequest,inspectthefeedabilityofthelubricantselectedbytheuserincentralizedlubricationsystems.Lubricationsystemsandtheircomponentsmanufac-turedbySKFarenotapprovedforuseinconjunctionwithgases,liquefiedgases,pressurizedgasesinsolution,vaporsorsuchfluidswhosevaporpressureexceedsnormalatmosphericpressure(1013mbar)bymorethan0.5barattheirmaximumpermissibletemperature. Particularattentioniscalledtothefactthathazardousmaterialsofanykind,especiallythematerialsclassifiedashazardousbyECDirective67/548/EEC,Article2,Para.2,mayonlybefilledintoSKFcentralizedlubricationsystemsandcomponentsanddeliveredand/ordistrib-

utedwithsuchsystemsandcomponentsafterconsultingwithandobtainingwrittenapprovalfrom SKF.

LC 502 controller EN Operating instructions for DuoFlex ... · (ProFlex, MonoFlex, or DuoFlex) and...

Documents

Transcript of LC 502 controller EN Operating instructions for DuoFlex ... · (ProFlex, MonoFlex, or DuoFlex) and...