Automatic Chain Lubricator – for Compac Technicians Only

Automatic Chain Lubricator

Installation and Operation

Wiki URL:
Written by: Clint Evenbly, Quality Engineer (http://compacwiki/display/DOCINS/Automatic+C
hain+Lubricator)

Authorised by: Clint Evenbly Model: n/a

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Standalone document
%20Lubricator/Automatic%20Chain%20Lubricator%20Control%20V2.0.pd
f)
Active Date: 8 March, 2011 Revision Number: 2.0

In this document

1. Introduction
2. Interface I/O and Wiring
3. SAM Configuration (SCP)
4. SSP Configuration
5. Operating the Chain Lubricator
6. Automatic Chain Lubricator Diagnostics
7. Notes on Upgrading to Automatic Chain Lubrication

1. Introduction
The chain lubricator operates a series of solenoids, one per sizer lane. These solenoids switch
the gravity fed flow of lubricant from the reservoirs to the carrier chains.

The chain lubricator has two modes, manual and automatic

2. Interface I/O and Wiring

The chain lubricator requires the first ten IO on port A of a 24V SAM. Four of these IO are
connected to external hardware, 2 outputs (one to open the solenoids, one to control the
Running/Re-Fill Pilot) and two inputs (one from the Man (ON) / Auto (Off) selector, one from
the Re-Filled push Button).

The remaining six IO are utilized in internal timers and IO linking (see below).

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Figure 1 - The Chain lubricator Physical Interface

Figure 2 - SAM connections

Figure 2 shows the connection between the SAM and the Chain Lubricator control box. The
internal wiring for the IO linking is also showed. The Chain Lubricator control box will house:
• 1x 2 Position selector with 1 NO contact for the Man (ON) signal
• 1x Illuminated push button with 1 NO contact for the Re-filled signal, and with a pilot light
indication
• 3x Commoning blocks (1 for +VDC towards solenoids, 1 for 0VDC towards solenoids and
1 for earthing the solenoids)
• The proper interconnection plugs, pins and cables for the interface with the SAM.

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3. SAM Configuration (SCP)

The chain lubricator must be installed onto Port A of a 24v SAM.
SAM 4020 firmware must be 1.7e or 1.11 (or later). All SAM 4040 firmware is compatible.

Name Description Links Flags Mode Index

IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
1. SOLENOIDS OUTPUT:Immediate ON / From Input ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
EXTERNAL Immediate OFF 10
To Output 1 1 1 1 1
4 18 00 03
IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
2. MANUAL(ON) INPUT: Timer Linked – From To Output ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
EXTERNAL Man (ON) Selector 5
To Input 6 1 1 1 1 1 1 1 1 1
F0 22 85
IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
3. RE-FILLED INPUT: ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
EXTERNAL
1 1 1 1
40 00 64
IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
4. RUNNING/ OUTPUT: Immediate ON / From ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
RE-FILL Immediate OFF Output 1
EXTERNAL 1
08 00 00
IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
5. Timer OUTPUT: Immediate ON/ Ctimer ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
INTERNAL Timed Remote Off Physically loaded by
connected to 6 2, Dec by 8 1 1 1 1 1
98 06 00
IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
6. Aux 4 INPUT: Immediate ON/ To Input 10 ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
INTERNAL Immediate OFF Physically From Input
connected to 5 2 1 1 1 1
From
Output 5
84 48 00
IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
7. Aux 2 INPUT: OFF Delay – To Output ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
INTERNAL Receives Rods from SCP 9
1 1 1 1 1 1 1 1
D0 40 0F
IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
8. Aux 1 INPUT: Timer Linked – To Output ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
INTERNAL Physically connected to 9 5
and 10 1 1 1 1 1 1 1 1 1
10 BD 84
IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
9. Aux 3 OUTPUT: Immediate ON/ From Input ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
INTERNAL Timed Global OFF (ON while 7
Sizer Running) Physically 1 1 1 1 1 1
connected to 8 and 10
48 0A 01
IOL TB INV AC IO NTT NL NT IOL4 IOL3 IOL2 IOL1 IOL0 IM2 IM1 IM0 ON3 ON2 ON1 ON0 OFF OFF OFF OFF
10. Aux 5 INPUT: OFF Delay Physically To Output ON2 ON1 ON0 DLY OFF OFF OFF DO 3 2 1 0
2 1 0
INTERNAL connected to 8 and 9 1 From
Input 6 1 1 1
From
Output 9
94 00 00
11.

12.

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The standard IO scan reload value is 20, which supports a large enough timer to handle sizers
with up to 1275 carriers.

Increase the IO scan reload value to 40 if the sizer has between 1275 and 2550 carriers.

4. SSP Configuration

4.1 Magic Numbers

It is intended that every sizer with a chain lubricator unit will have AutoChainLubricatorExists
set to true and then AutoChainLubricatorEnabled will be set on a site by site basis depending
if the customer prefers automatic lubrication or if they wish to implement a separate scheduled
manual lubrication system.

AutoChainLubricatorExists

The AutoChainLubricatorExists magic number activates the appropriate screens in the

software. If this magic number is set to false the auto chain lubricator software will be
completely inactive and the chain lubricator will need to be configured and operated as per
SAM 4020 - Chain Lubricator Control V1 6.pdf.

AutoChainLubricatorEnabled

AutoChainLubricatorEnabled only has an effect if the AutoChainLubricatorExists magic

number is set to True. The AutoChainLubricatorEnabled magic number is linked to the Auto
Chain Lubrication Enabled option in the Automatic Chain Lubricator configuration screen
and determines if the automatic lubrication features of the software are active.

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If AutoChainLubricatorEnabled is set to False, the software will continue to monitor the

machine as follows:
• Tracking when an automatic lubrication cycle is due
• Tracking lubricant use in manual mode
• Logging and tracking manual lubrication cycles
• Note that the software will not start an automatic lubrication cycle, nor will it warn the
operator if an automatic lubrication cycle is due.

4.2 Rod Train

To provide the rod signal to the Automatic Chain Lubricator SAM, a rod train must be created
to IO 7 of every chain lubricator SAM (in the example above it is a dual frame machine).

4.3 Automatic Lubricator IO Setup

Note: A row is automatically added for every frame configured in the system. If a frame does
not have a lubricator unit present on it, leave the row empty.

Name IO Description
Lubricator Activated Input 1 Read by the software to determine when the lubricant
solenoid is on.
Activate Lubricant Output 6 Used by the software to activate the lubricant solenoid.
Refill Light Output 4 The running/refill pilot light on the lubrication unit.
Manual Running Input 2 The Manual/Auto switch on the lubrication unit.
Refilled Button Input 3 The refill button on the lubrication unit.
Manual Mode Paused Input 9 Read by the software to determine if the manual process
has paused.
Manual Mode Timing 5 Used by the software to configure the SAM manual
Output mode operation time.

The Auto Lubricator IO tab is available in the General IO Configuration window, which is
available only at the Technician access level and above.

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4.4 SSP Chain Lubricator Setup

Default access level: Technician access level:

Run time between lubrication cycles (hours)

The machine run time between automatic lubrication cycles. The machine is said to be running
if the sizer is processing rods. 120 hours is recommended.

Lubrication distance (revolutions)

The number of full chain revolutions to lubricate for during automatic lubrication cycles. A value
of 2 is recommended and means each carrier will pass under the lubrication block twice during
the lubrication cycle. During automatic lubrication cycles, the sizer speed is taken into account to
exactly achieve the specified number of lubrication cycles.

Minimum lubrication speed (rods/min)

The Automatic mode minimum sizer speed. If the sizer falls below this speed at any time during
the lubrication process, the process will be paused. When the sizer climbs above this speed,
the process will resume. Upon resuming lubrication, any previous part revolutions are discarded
i.e. if 1.6 revolutions were complete before the pause, it will resume from 1.0 revolutions to
guarantee that each section of the chain received 2 lubrication cycles.

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Seconds of lubricant used for refill alert

The lubricant reservoir capacity (minus a safety factor). During all lubrication cycles the
lubricant use is tallied and when it exceeds this value the operator is prompted to refill the
reservoir. A value of 640s is recommended as the lubricant level should be at approximately
25% of full.

Manual mode operation time (seconds) – for the Manual mode run time.
This is completely separate from the Lubrication distance setting, which only applies to
Automatic mode. It is recommended you configure this so that the lubricator runs for two
revolutions at a sizer speed of 600 rods/min. Divide the number of carriers on the sizer by 5
and enter it in here.
The IO 5 index holds the manual mode timer. Behind the scenes the automatic chain lubricator
software is setting this value based on {IO 5 index} = {Operation time (s)}/({IO scan reload
value}*50).

5. Operating the Chain Lubricator

Both modes require that the sizer software is running and also that the sizer is running.

5.1 Automatic Mode

For chain lubrication to be fully active:
• The AutoChainLubricatorExists magic number must be set to True;
• The Automatic Chain Lubrication Enabled checkbox must be checked (or the
AutoChainLubricatorEnabled magic number set to true, which is the same thing);
• The Man (ON) / Auto (Off) switch must be set to Auto
(Off).

After the defined machine run time, the software will start
an automatic lubrication cycle and a small notification is
created in the lower right hand corner of SSP and the
running light on the lubricator unit will illuminate.

• If the Sizer falls below the configured minimum

lubrication speed the lubrication cycle is paused. When
the sizer climbs back above the minimum lubrication
speed the lubrication process will resume.

5.2 Manually Initiated Automatic Mode

Lubrication can be started from the Automatic Chain Lubricator Configuration screen by
clicking the Lubricate Now button.
Lubrication cycles started this way behave identically to regular Automatic lubrication cycles:
• The lubrication distance is used not the manual mode operation time.
• Falling below the minimum lubrication speed pauses the cycle.

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5.3 Manual Mode (from Hardware)

When the Man (ON) / Auto (Off) switch is switched to the
Man (ON) position, a manual lubrication cycle is activated
and a small notification is created in the lower right hand
corner of SSP, and the running light on the lubricator unit
will illuminate.
• The manual lubrication cycle will run for the length of
time that is configured in SSP. When it is complete, the
running light will go out and the flow of lubricant will
stop.
• If the sizer is stopped during the manual lubrication cycle, the timer will pause. The timer
will resume once the sizer is started.
• If the Man (ON) / Auto (Off) switch is switched to the Auto (Off) position, the manual
lubrication cycle will be cancelled and lubricant flow will immediately stop. There is no way
to resume the previous cycle. Switching back to Man (ON) will start a new cycle with a fresh
timer.
• When a manual lubrication is complete the Man (ON) / Auto (Off) switch should be put
back into the Auto (Off) position so that automatic lubrication cycles can run interrupted.

5.4 Refilling the Automatic Chain Lubricator

The software is tracking lubricant use and when the Lubricant used for refill alert is reached
the operator will be prompted to refill the lubricant reservoirs.

The operator must now either refill the lubricator unit, or postpone the refill. Note that if one
reservoir has more lubricant than others, it may be blocked. You must clear any blockages.

The process of refilling the lubricator unit is:

• Refill the lubricant reservoirs;
• Push the flashing green button on the lubricator unit;
• Return to the PC and click Done;
• Enter your name when prompted. (All lubrication operations are logged).

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To postpone the refill click Remind me tomorrow and enter your name when prompted.

If the refill is postponed, the operator will be reminded at 10am every day or after 24 hours.

Operators can initiate the refill process at their convenience in the Automatic Chain
Lubricator configuration screen by using the Refill now button.

6. Automatic Chain Lubricator Diagnostics

All automatic chain lubricator events are logged to the SSP events log.
This includes:
• When all lubricator operations start and stop
• When the operator is prompted to fill the reservoirs, and their response
• When the operator fills the reservoirs, and the name entered

All timers and counters relating to the automatic chain lubricator can be viewed in the SCP
Other Diagnostics in the AutoChainLubricator tab.

7. Notes on Upgrading to Automatic Chain Lubrication

1. Enable auto chain lubrication in magic numbers.
2. Adjust the SAM IO config:

• The IO 3 mode and index values have been changed.

• The IO 5 index has been changed.
3. Configure the Auto Lubricator IO in the General IO screen.
4. Configure the SSP Chain Lubricator options.

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