PRODUCT MANUAL

PROGRAMMABLE LUBRICATION
CONTROLLER

Part No. 9252

 DISCLAIMER

© Remote Control Technologies Pty Ltd.

■ No part of this manual may be reproduced, copied, translated, or transmitted in any form or by any means without the written
permission of RCT.

■ Information provided in this manual is intended to be accurate and reliable. However, RCT assumes no responsibility for its use or
infringements upon the rights of third parties that may result from its use.

■ All examples and diagrams shown in this manual are intended only as an aid to understanding the text, not to guarantee operation.
RCT will accept no responsibility for actual use of the product based on these illustrative examples.

■ Please contact your nearest RCT branch for more information concerning applications in life critical situations or high reliability.

■ RCT reserves the right to make changes to any product herein to improve reliability, function or design. All specifications are subject
to change without notice.

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 Contents

General Safety Warnings 6

Personal Safety 6
Machine 6
Product 6

Product Overview 7
Features and Functions 7
Operation and Use 8
Control Unit 8
Inputs 8
Outputs 9
LED Indication 9
Software Options 9

Installation Guide 10
Wiring Connections 10
Wiring Connections for part number 4606 and 3560 10
Wiring Diagrams 11
− Single Bank System – External Wiring Diagram (427i) 11
− Dual Bank System – External Wiring Diagram (427h) 12
− Basic Programming Adaptor Lead – External Wiring Diagram (427j) 13
− In-Line Programming Adaptor Lead – Loom Configuration (423a) 14

Calibration 15
Software Detailed Description and Advanced Configuration 15
Home Screen 15
− Simulating a Lube Controller 15
− Connecting via COM Port 16
− Upgrading the Device 16
Main Setup Screen 16
− Layout 16
Section 1 – Tabbed Browsing of Devices 17
Section 2 – Toolbar Buttons 17
Section 3 – Inputs Section 18
Section 4 – System State 20
Section 5 – Outputs/Indicators 22
Testing and Simulation 23
− Testing a Physical Lube Controller 23
− Running a Simulation 23
Factory Default Settings 24
− Lubrication Options 24
− Timer Settings 24
− Alarm Options 24
− Advanced Settings 24

Service Information 24
Service Schedule 24
Service Procedure 24

Parts List 25
Technical Specifications 25

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 Compliance and Standards 25
Troubleshooting 25
Glossary 26
Warranty 26
Revision History 27

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 Table of Figures
Figure 1 Programmable lubrication controller .................................................................................................. 7
Figure 2 Drawing 427i Single bank system external wiring diagram .............................................................. 11
Figure 3 Drawing 427h Dual bank system external wiring diagram ............................................................... 12
Figure 4 Drawing 427j Basic programming adaptor lead external wiring diagram ......................................... 13
Figure 5 Drawing 423a – In-line programming adaptor lead loom configuration ........................................... 14
Figure 6 Lube controller application ............................................................................................................... 15
Figure 7 Home screen – lube controller application ....................................................................................... 15
Figure 8 Layout of the main set-up screen ..................................................................................................... 16
Figure 9 Device (a) tab & serial number, and (b) firmware version ................................................................ 17
Figure 10 Toolbar for (a) general connected device, and (b) simulated lube controller ................................. 17
Figure 11 Inputs layout ................................................................................................................................... 18
Figure 12 Options section for a lube controller ............................................................................................... 19
Figure 13 Device Info example ....................................................................................................................... 20
Figure 14 Lube controller counters ................................................................................................................. 20
Figure 15 Timers running for a lube controller................................................................................................ 20
Figure 16 Outputs layout ................................................................................................................................ 22
Figure 17 LEDs section .................................................................................................................................. 22
Figure 18 Override example ........................................................................................................................... 23

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 General Safety Warnings
Personal Safety
■ Everyone is responsible for safety.
■ The installer/service personnel should be trained and authorized to complete the required work.
■ Ensure that the machine is safely isolated during installation and testing to protect all personnel.
■ Complete all required risk assessments and job safety analysis (JSA) before commencing work.
■ Observe all site specific and machine OEM procedures regarding the following:
– working at heights
– working in heat
– working in confined spaces
– all other site specific occupational health and safety (OH&S) procedures

Machine
■ Carry out all pre-start operations as per site and machine OEM procedures.
■ Ensure the machine is safely isolated during installation and testing to protect the machine and other
equipment in the area.
■ Do not operate any machine with a known fault and report all findings to the supervisor in writing.
■ Test and operate machine as per machine OEM and site procedures.
■ Read and understand machine and site specific operational and testing instructions.

Product
Before applying power to the equipment, the user/repairer/installer must read all product instructions. If in
doubt, seek assistance.
■ Ensure electrical connections are made as per RCT’s recommendations. Test circuits prior to connecting
power to any component.
■ The equipment contains no user serviceable parts inside. Return the unit to RCT for repairs.
■ Retain product and installation instructions for future use.
■ Ensure that RCT’s recommended service procedures are included in the machine’s service routine.
■ Observe all machine, site and RCT product warnings.
■ Follow all machine, site and RCT product operating procedures at all time.

The application of safety should not be limited to the above recommendations.

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 Product Overview

Figure 1 Programmable lubrication controller

The Muirhead® Programmable Lubrication Controller, part number 9252, is designed for flexibility and is used
to automate the grease injection system on a machine.
The programmable lubrication (lube) controller is capable of operating in many different modes to suit multiple
lubrication systems available on the market. In the standard pump solenoid valve pressure switch
arrangement, the system can be programmed so that the pump can act as a reciprocating pump where it
requires a pulse circuit or it can just switch a pump on. The system provides the option to use a pressure
switch. The pause and pump periods can be adjusted from 0.5 seconds to up to 24 hours. It can also be easily
configured to act as a swap version where it activates a lube cycle on one bank for a period, then swaps over
and operates a second bank with full pressure switch monitoring.
The system has many diagnostic capabilities and when connected to the custom software package, the
complete system can be monitored.

Features and Functions

■ Pressure switch monitoring
■ Pulse or continuous pump
■ Adjustable pause and pump periods from 0.5 seconds to 24 hours
■ Swap between banks
■ Manual pump mode
■ Grease low level indication
■ Customised software
■ Inbuilt diagnostics
■ 12 or 24 volt machines
■ Suits various lubrication systems
■ Fully software configurable to suit all machine types
■ One panel to suit all machines on site
■ Modular design
■ Internal alarm

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 Operation and Use
The Muirhead® Programmable Lubrication Controller has been designed with flexibility in mind. The system is
capable of operating in many different modes which suit multiple lubrication systems.

Control Unit
The lube controller has been designed to be an in-cabin mounted device.

Note
The lube controller is not IP rated for external mount.

The lube controller incorporates a manual lube cycle button that activates a cycle if pushed, as well as an
internal audible alarm.
The lube controller has LED indication and inbuilt diagnostics to aid fault finding. It also incorporates options
for low level detection, an external manual lube button and also an external alarm circuit. All calibrations and
programming are performed using a user-friendly software program via a notebook computer.
The programs can be saved and later loaded into multiple units if required and can be calibrated to suit all
types and variations of machines.
The power supply requirements are 8 to 36 volts dc and therefore suits all 12 and 24 volts dc machines.
The information below describes the operation of every function of the programmable lube controller, including
the inputs, outputs, LED indicators, and software options.

Inputs
Pressure switch 1 input This input can be configured to sense a positive or a negative and can be
normally open or normally closed. The options are software adjustable. The
standard configuration is negative and normally open, only closing when
pressure is achieved.
Pressure switch 2 input This input can be configured to sense a positive or a negative and can be
normally open or normally closed. The options are software adjustable. The
standard configuration is negative and normally open, only closing when
pressure is achieved. This input is only used on systems that require two
pressure switch inputs.
Low grease level input This input can be configured to sense a positive or a negative and can be
normally open or normally closed. The options are software adjustable. The
standard configuration is negative and normally open, only closing when a low
level is detected. This input is optional, if level monitoring is not available, do
not use this input.
External lube cycle input This input can only sense a positive signal. However, it can be configured to
be normally open or normally closed. The options are software adjustable.
The standard configuration is normally open, closing when a lube cycle is
required. This input is optional and acts exactly the same as the cycle button
on the lube controller.
Cycle push button Pressing this button activates a lube cycle. It bypasses the pause period. It is
generally used by the operator if they think extra lube is required. An additional
feature of this push button is when the unit is in alarm mode pressing this
button will mute the alarm for 10 minutes.

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 Outputs
Pump output This connection is a positive switching FET output. Rated up to 8 A, this output
is used to operate the lube pump. The active time period for this output is
software configurable.
Pulse output This connection is a positive switching FET output. Rated up to 8 A, this output
is used to control a pulsing circuit to drive a reciprocating pump. Both the pulse
on and off periods for this output are software configurable. This output can
also act as a swap output for dual bank systems. The selection of the swap
circuit is software configurable.
Alarm output This connection is a positive switching FET output. Rated up to 2 A, this output
is used to activate a remote mount alarm or visual indicator. This circuit is
optional due to the fact that the lube controller has an internal audible alarm.
The alarm output is software configurable to be on continuous pulse failure
warnings and not to operate at all.

LED Indication
Power on This indicator illuminates green when the unit is switched on.

Pump This indicator illuminates green when the pump output is active.
Pulse This indicator illuminates green when the pulse output is active. For a lube
controller configured for a two lube bank system, the indicator indicates that
the swap solenoid is active.
Press 1 This indicator illuminates amber when pressure switch 1 is active. It displays
one pulse if the lube cycle failed to reach pressure within its lube period,
indicating a possible broken line. It displays two pulses if the lube pressure is
achieved too quickly, indicating a possible blocked line.
Press 2 This indicator illuminates amber when pressure switch 2 is active. It displays
one pulse if the lube cycle failed to reach pressure within its lube period,
indicating a possible broken line. It displays two pulses if the lube pressure is
achieved too quickly, Indicating a possible blocked line.
Level This indicator illuminates red and pulses whenever the low grease level is
detected.

Software Options
Lockout pump When enabled, the lubrication pump is locked out after an open failure.
Lube at power up When enabled, the lube cycle is activated as soon as power is applied.
Two lubes banks (swap) When enabled, the lube controller operates two lubrication banks by operating
as a swap circuit.
Pulse low grease alarm The low grease alarm can be set to either pulsed or continuous during a low
grease fault.
Pulse low grease output The low grease output can be set to either pulsing or continuous during a low
grease fault.
No pressure switch The lube controller can be set up to operate with no pressure switch inputs.
Therefore no fault conditions occur when set up this way.
No sonar alert The internal sonar alert can be disabled.
External manual lube When selected it allows the unit to accept an input from an external manual
lube switch.

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 Installation Guide
1. Install the lube controller in a suitable location away from moisture and dust, preferably in the cabin area
where the operator has access.
2. Refer to the wiring table below and the specific wiring diagrams (that suits the system being installed) in
this manual to connect the lube controller. It is recommended that the wiring is installed alongside the OEM
wiring ensuring that it is secured at regular intervals; this will provide protection from heat and abrasion,
and any other excess damage that may occur with extended vehicle operation. When securing the wiring
to the OEM wiring, ensure that the loom is away from moving vehicle parts which could lead to loom
damage.
The following table details the different pin and wiring connections available on the lube controller.

Wiring Connections
No. Signal Description
1 Ignition 8 to 36 Vdc
2 Ground 0 Vdc
3 Output (pump solenoid) 8 A inductive (supply volts)
4 Output (pulse solenoid) 8 A inductive (supply volts)
5 Output (external alarm) 2 A resistive (supply volts)
6 Digital input (pressure switch 1) Active − or + (default is − )
7 Digital input (pressure switch 2) Active − or + (default is − )
8 Digital input (low lube level) Active − or + (default is − )
9 Digital input (external manual cycle) Active +
10 Data ground 0 Vdc
11 RS 232 RX (receive) Data
12 RS 232 TX (transmit) Data

Wiring Connections for part number 4606 and 3560

When removing one of these part numbers and replacing with a 9252 please use connection details below.

4606 and 3560 Wiring Connections 9252 Wiring Connections

No. Colour 8-pin Plug 12-pin Plug
1 Black Earth to Pin 2
2 Green Fault alarm +VE (optional) to Pin 5
3 White Pressure switch (N/O) to Pin 6 (Pin 7 optional second pressure switch)
4 Orange +12/24 V supply to Pin 1
5 Black/white Grease pump solenoid –VE to Not Used
6 Purple Grease pump solenoid +VE to Pin 3
7 Green/yellow Fault alarm –VE (optional) to Not Used
8 - Not used

There will be extra features when installing the 9252 please refer to the manual for connection details on these.

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 11 | 28
1 2 3 4 5 6 7 8 9 10 11 12
REV ZONE DESCRIPTION BY DATE
update titleblock and label
1 logo GT 04/08/15
A A
B B

Figure 2 Drawing 427i Single bank system external wiring diagram

POWER LUBRICATION
CONTROL
PUMP
PULSE
PRESS 1
C CYCLE C
PRESS 2
LEVEL
PART No. 9252 12/24VDC
12
11
10
D D
9

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8
Single Bank System – External Wiring Diagram (427i)

7
ALL DIMENSIONS IN MILLIMETERS
6 UNCONTROLLED DOCUMENT
SCALE
5
NTS A4
4 3rd ANGLE
E PROJECTION E
3
2 www.rct.net.au
COPYRIGHT - ALL RIGHTS RESERVED
1 This drawing is the property of REMOTE
CONTROL TECHNOLOGIES PTY LTD (RCT),
and is not to be copied or used in whole or in
part for any purpose without the express
authority of RCT. The drawing is to be returned
to RCT, on demand.
F F
+ +
+ LUBRICATION

L
- CONTROL UNIT TO
- - SUIT 9252 CIRCUIT
FOR SINGLE BANK
SYSTEM
EXTERNAL WIRING
G G
Wiring Diagrams

+
IGNITION EARTH GREASE PULSE LUBE FAIL GREASE LOW GREASE MANUAL
PUMP SOLENOID WARNING PRESSURE LEVEL LUBE SWITCH
SOLENOID (OPTIONAL) SWITCH (OPTIONAL) (OPTIONAL) PART
----
NO
BANK 1 STOCK
CODE ----
BY BT
DRN EH DATE 01/07/11
APPD BT DATE ----
H SHEET
1 of 1 H
STATUS
Released
DWG No REV
427i 1
1 2 3 4 5 6 7 8 9 10 11 12
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1 2 3 4 5 6 7 8 9 10 11 12
REV ZONE DESCRIPTION BY DATE
updated titleblock and
1 label logo GT 04/08/15
A A
B B
POWER LUBRICATION

Figure 3 Drawing 427h Dual bank system external wiring diagram

CONTROL
PUMP
PULSE
C PRESS 1 C
CYCLE
PRESS 2
LEVEL
PART No. 9252 12/24VDC
12
11
D 10 D
9
8
7
ALL DIMENSIONS IN MILLIMETERS
6
Dual Bank System – External Wiring Diagram (427h)

UNCONTROLLED DOCUMENT
5 SCALE
4
NTS A4
3rd ANGLE
E 3 PROJECTION E
2
www.rct.net.au
1 COPYRIGHT - ALL RIGHTS RESERVED
This drawing is the property of REMOTE
CONTROL TECHNOLOGIES PTY LTD (RCT),
and is not to be copied or used in whole or in
part for any purpose without the express
authority of RCT. The drawing is to be returned
to RCT, on demand.
F + + F
+

L
- LUBRICATION
- -
CONTROL UNIT TO
SUIT 9252 CIRCUIT
FOR DUAL BANK
SYSTEM
WIRING CONNECTIONS
PIN FUNCTION + EXTERNAL WIRING
G IGNITION EARTH GREASE SWAP LUBE FAIL GREASE GREASE LOW GREASE MANUAL G
1 IGNITION 12 - 24 VOLTS PUMP SOLENOID WARNING PRESSURE PRESSURE LEVEL LUBE SWITCH
2 EARTH SOLENOID (OPTIONAL) SWITCH SWITCH (OPTIONAL) (OPTIONAL)
3 PUMP SOLENOID BANK 1 BANK 2
PART
4 GREASE BANK SWAP SOLENOID NO ----
5 EXTERNAL ALARM STOCK
CODE ----
6 PRESSURE SWITCH 1 BY BT
7 PRESSURE SWITCH 2 DRN EH DATE 01/07/11
APPD BT DATE ----
8 LOW LEVEL SWITCH
H SHEET
1 of 1 H
9 MANUAL LUBE INPUT EXTERNAL STATUS
10 DATA GROUND Released
11 DATA RECEIVE DWG No REV
427h 1

12 | 28
12 DATA TRANSMIT
1 2 3 4 5 6 7 8 9 10 11 12
 13 | 28
1 2 3 4 5 6 7 8 9 10 11 12
REV ZONE DESCRIPTION BY DATE
CORRECT TEXT LABEL
1 BT 08/07/11
ON PIN 1
updated titleblock and
2 label logo GT 04/08/15
A A

Figure 4 Drawing 427j Basic programming adaptor lead external wiring diagram
B B
POWER LUBRICATION
CONTROL
PUMP
PLUGS INTO COMPUTER
C PULSE SERIAL PORT C

6
C

2
PRESS 1 FRONT

7
CYCLE A

3
Basic Programming Adaptor Lead – External Wiring Diagram (427j)

8
B

4
PRESS 2

9
3314

5
LEVEL
PART No. 9252 12/24VDC
D 12 D
11

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10
9 1
6 ALL DIMENSIONS IN MILLIMETERS
2
8 7
3
UNCONTROLLED DOCUMENT
8 BACK SCALE
7 9
4
5
NTS A4
3rd ANGLE
E 6 PROJECTION E
5
www.rct.net.au
4 COPYRIGHT - ALL RIGHTS RESERVED
This drawing is the property of REMOTE
3 CONTROL TECHNOLOGIES PTY LTD (RCT),
and is not to be copied or used in whole or in
part for any purpose without the express
authority of RCT. The drawing is to be returned
2 to RCT, on demand.
1
F F
BASIC
ADAPTOR PLUGS INTO PROGRAMMING
ADAPTOR LEAD
LUBRICATION CONTROLLER
TO SUIT 9252
12-24 VOLTS EARTH LUBRICATION
CONTROL UNIT
G G
POWER IS REQUIRED TO
POWER THE CONTROLLER
PART
NO ----
STOCK
CODE ----
BY BT
DRN EH DATE 01/07/11
APPD BT DATE ----
H SHEET
1 of 1 H
STATUS
Released
DWG No REV
427j 2
1 2 3 4 5 6 7 8 9 10 11 12
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1 2 3 4 5 6 7 8 9 10 11 12
REV ZONE DESCRIPTION BY DATE
title changed, remove
1 serial port details, redraw DAS 05/08/11
to loom standard
ADD SLEEVING PART
2 DAS 15/08/11
NUMBERS
CHANGE WIRE
A 3 COLOURS TO KROFLEX DAS 18/08/11 A
NUMBERED WIRES
added TO PROG LEAD
4 DAS 25/10/11
TO C
10488 specific details
removed so drawing is
5 DH 16/05/14
now generic for
10488/9252
updated titleblock and
6 label logo GT 04/08/15
12v removed from table
7 G1 JunW 05/04/18
added apns, changed
8 var. GJS 24/01/19
wire colour at A12/CC
(10488 / 9252)

Figure 5 Drawing 423a – In-line programming adaptor lead loom configuration

B B
C C
A11 11
A
In-Line Programming Adaptor Lead – Loom Configuration (423a)

A10 10 TO PROGRAMMING LEAD

B C (3314)
A12 GN/YL
C
D D
(3229)
12/24VDC
GN/YL CC
12 12
ALL DIMENSIONS IN MILLIMETERS
11 CA
11 11 UNCONTROLLED DOCUMENT
10 CB SCALE
10 10 NTS A4
9 B9 A9 9
E
9 9 3rd ANGLE
E
PROJECTION
8 B8 A8 8
8 8
7 B7 A7 7 www.rct-global.com
7 7 COPYRIGHT - ALL RIGHTS RESERVED
A 6 B6 A6 6 B This drawing is the property of REMOTE
6 6 CONTROL TECHNOLOGIES PTY LTD (RCT),
and is not to be copied or used in whole or in
part for any purpose without the express
5 B5 A5 5 authority of RCT. The drawing is to be returned
5 5 to RCT, on demand.
4 B4 A4 4
4 4
3 B3 A3 3
F 3 3 F
2 B2 A2 2
2 2
IN LINE
1 B1 A1 1 PROGRAMMING
1 1
ADAPTOR LOOM TO
(2022) (2186) SUIT 10488 AND 9252
(1959) (1944)
WIRING CONNECTIONS
EXTERNAL WIRING
PIN FUNCTION
G ADAPTOR PLUGS IN LINE G
1 24 VOLTS
WITH MACHINE WIRING
2 EARTH
3 PURGE SOLENOID
PART
4 NO 10492
5 STOCK
CODE MH-APC-L02
6 BY BT
7 DRN EH DATE 13/05/11
APPD BT DATE 13/05/11
8
H SHEET
1 of 1 H
9 MANUAL PURGE INPUT EXTERNAL STATUS
10 DATA GROUND Released
11 DATA RECEIVE DWG No REV
423a 8

14 | 28
12 DATA TRANSMIT
1 2 3 4 5 6 7 8 9 10 11 12
 Calibration
Software Detailed Description and Advanced Configuration
The lubrication controller uses the proprietary Muirhead® Lube Controller Software package installed on a
laptop for setting and adjusting the options. The laptop requires either a serial port or a USB-to-serial adaptor
to enable serial communications between the laptop and the lube controller.
The following part numbers are required when programming the lube controller:

Part No. Item Qty

11199 Kit Programming Lube Controller (part number 9252) 1
2694 Adaptor, USB-to-Serial 1

This software is a single executable (.exe) file and can be launched by double-clicking its icon.

Figure 6 Lube controller application

Home Screen
The home screen appears when launching the Muirhead® Lube Controller software. You can return to the
home screen at any time by clicking on the gear symbol icon ( ) in the top left-hand corner of the screen.
The home screen is used to create simulated devices in addition to selecting the COM port(s) that devices are
connected to.

Figure 7 Home screen – lube controller application

Simulating a Lube Controller

A lube controller can be simulated to allow for the adjustment of the unit’s settings then testing without a device
physically connected to the PC/laptop. Refer to Figure 7.
To simulate a lube controller, click Create Lube Controller. A new screen is then displayed where the device
can be set up and the settings saved. More information about changing the device settings is discussed further
on in this document.

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 Connecting via COM Port
Devices can also be connected and set up directly via one of the available COM ports on the computer running
the software. Multiple devices can be connected at once, limited only by the number of COM ports that you
have available on the PC/laptop. Refer to Figure 7, section 2.
The serial comms is connected to pins 10, 11 and 12 on the lube controller. Drawing 427j on page 13 shows
the connections needed. Power also needs to be applied to the device when programming.
Alternatively, a special purpose inline adaptor lead (part number 3314) can be purchased. The inline adaptor
lead would allow the programming and calibration to occur while the lube controller is still connected to the
machine.
To connect to a device, select the checkbox of the COM port to which the device is connected. If you are using
a USB-to-serial converter, then you may have to refresh the list of COM ports once the drivers are loaded and
the converter is recognised.
The lube controller must be powered when communicating with the software. A new screen will now be
displayed where the device can be set up and the settings saved. More information about changing the device
profile is discussed further on in this document.

Upgrading the Device

If the version of firmware inside the device is out-of-date, then the Muirhead® Device Tool software will detect
this when a connection is first made, and the software will display a request to update the firmware. Click Yes,
and the software will proceed to load the new firmware and will display the updating progress on a status bar.
It is recommended that the firmware be allowed to update before proceeding.

Main Setup Screen

Layout
The main set-up screen looks very complex but can easily be understood when broken up into individual
sections.

Figure 8 Layout of the main set-up screen

No. Description
1 Tabbed browsing of devices
2 Toolbar buttons
3 Input settings and input options
4 Functional set-up of the device and customisable device information
5 Output settings
6 External wiring schematic

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 Section 1 – Tabbed Browsing of Devices
Each lube controller that you connect or simulate through the software is displayed in a tab. You can easily
switch between devices by selecting the tab of the required device. Clicking the small tab with the gear symbol
icon will display the home screen to enable connection of or simulate another lube controller.
Simulated lube controllers can be closed by clicking on the small cross in the top right-hand side of the tab.
Physically connected lube controllers can be disconnected at any time as any changed settings are
automatically saved.
The serial number of the device can be found underneath the tabs on the top left-hand side of the screen as
shown in Figure 9(a). This information is not available for simulated devices and is simply displayed as
Simulated Device – refer to Figure 8, section 1. The firmware version can be found at the bottom right-hand
corner of the screen as shown in Figure 9(b).

Figure 9 Device (a) tab & serial number, and (b) firmware version

Section 2 – Toolbar Buttons

Toolbar buttons allow the management of the settings profile you have created, such as loading a saved profile.
The buttons that are displayed in the toolbar depend on whether a device is connected or if the device is
simulated.

Figure 10 Toolbar for (a) general connected device, and (b) simulated lube controller

Button Description
Load a saved settings profile to the connected lube controller or simulated lube controller.

Save the current settings profile to the computer.

Reset all settings back to factory default settings.

Simulates a power cycle of the device.

Pause the simulation (simulated devices only).

Run the simulation using the current settings profile (simulated devices only).

Run a simulation with increased speed using the current settings profile (simulated devices only).

Close the simulated device (simulated devices only).

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 Section 3 – Inputs Section
The inputs section allows for the configuration of inputs for the operation of the unit. The inputs section is
always on the left-hand side of the screen. Refer to Figure 8, section 3 in this document.
Inputs can be configured to allow for various sensors and switching configurations to cater for a multitude of
machines with differing input sensors or devices.

Layout of Inputs Section

The input options are listed in the input section.

Figure 11 Inputs layout

The pin number of the input precedes the input name. This can be beneficial when fault finding and testing is
required.
The configuration of the input can be modified using the following two methods;
 Method 1
Click next to the input which will display each setting one line at a time (refer to Figure 11). Clicking the
current setting will present list on the screen showing the options for that setting.
 Method 2
A quick way for experienced users to change input setting by clicking the icons to the right of the input
name. These icons also serve as a quick visual indication of the state of the input.

Input Configuration
All lube controllers have the following input settings:

Setting Description
Input mode Active closed means that the input is classed as being on when the switch is closed. Active
open means that the input is classed as being on when the switch is open. This setting
basically inverts the on/off state of the input.
Pull-up mode Pulled up means that the internal circuitry of the lube controller is pulled high and hence
the input is looking for the switch being closed to ground. Pulled down means that the
internal circuitry of the lube controller is pulled to ground and hence the input is looking for
the switch being closed to positive.
Active Tells the user whether the lube controller is detecting a valid signal on the input (this cannot
be edited and hence is greyed out).
Enabled When true the input is enabled. When false the input is disabled (i.e. not in use).
Voltage Tells the user the voltage the internal processor is reading. Note: When the input switch is
open circuit, the processor will read its pull-up/pull-down voltage (this cannot be edited and
hence is greyed out. Simulated lube controllers do not display a voltage).

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 Options
The options in the options section directly below the inputs section affect how the device behaves.

Figure 12 Options section for a lube controller

No. Option Description

1 Lockout Pump When enabled, the lubrication pump is locked out after an open failure. Manual
Cycles lubrication cycles are permitted when the lubrication pump has been locked out.
The number of manual cycles can be configured. If any of the manual lubrication
cycles succeed, the device returns to operational mode. Otherwise, the device
can be reset by cycling the power off and then back on.
2 Lube at Power-up When enabled, a lubrication cycle is activated as soon as power is applied.
3 Alarm Output When this option is set to ‘Pulsed’, the alarm output pulses once every 10
seconds when the lube controller is detecting a low grease fault. Otherwise,
when this option is set to ‘Continuous’, the alarm output is on continuously when
the lube controller is detecting a low grease fault.
4 Pulse Low When this option is set to ‘Pulsed’, the low grease output pulses twice every
Grease Output second when the lube controller is detecting a low grease fault. Otherwise, when
this option is set to ‘Continuous’, the alarm output is on continuously when the
lube controller is detecting a low grease fault. It should be noted that the external
manual lube input must be disabled and the low grease output must be enabled.
5 Two Lube Banks When the two lube banks option is set to ‘Present’, the lube controller will operate
two lubrication banks by operating as a swap circuit. The pulse functionality is
disabled as the output is instead used to drive a swap solenoid. A pressure
switch is needed for each grease bank. When the two lube banks option is set
to ‘Not Present’, the lube controller will operate only the first lubrication bank.

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 Section 4 – System State
The system state section (Figure 8, section 4) displays the device information, diagnostics, counters and
device configurations. The system state section is always the centre column of the screen.

Device Information
Device information consists of fields which can be edited to record details relating to the setup and installation
of the device. This device Information is stored in the device itself. The general fields are:
■ Device Name
■ Install Date
■ Install ID
■ Install Type
■ Install Comments
There is currently no rule on the contents of each field; this may change in the future as more devices are
configured.

Figure 13 Device Info example

Counters
The lube controller has diagnostic counters which record the number of times certain events occur. This
information is displayed in the counters section of the system state section.

Figure 14 Lube controller counters

There is diagnostic material contained in the device information section. This information is mainly used by the
manufacturer and as such, it will not be discussed here.

Timers and Device Function Specifics

The last section in the system state section (Figure 8, section 4) is for timers and function specifics.
Timers can be set up simply by changing the time. All timers use the format of HH:MM:SS. The seconds field
can be adjusted in increments of 0.1 second. The timers section can also be used as a visual indication of the
progress of that timer when running the lube controller.

Figure 15 Timers running for a lube controller

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 No. Timer Description
1 Bank 1 Active Time that bank 1 is active during a lubrication cycle (default: two minutes).
2 Bank 2 Active Time that bank 2 is active during a lubrication cycle (only applicable when 2 lube
banks enabled) (default: two minutes).
3 Bank 2 Skip Number of lube cycles that bank 2 is inactive for (i.e., skipped) (default: 0).
4 Blockage The amount of time after lubrication cycle starts where a build-up of pressure
registers as a blockage (default: 3 seconds).
5 Mute Period When enabled, allows the user to silence any alarms for the set period by pressing
the cycle button (default: 10 minutes).
6 Pulse Off Off period for the pulse output (default: 0.5 seconds).
7 Pulse On On period for the pulse output (default: 0.5 seconds).
8 Pump Pause The amount of time that the lube controller waits before starting a new lubrication
cycle (default: 15 minutes).

Note
If an incorrect time is entered, or the time falls outside the acceptable range for that timer, then it will revert
back to the previous value.

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 Section 5 – Outputs/Indicators
The output/indicators section (Figure 8, section 5) allows for the configuration of outputs as well as options for
the operation of the outputs. The output/indicators section is always on the right-hand side of the screen.
Outputs can be configured to suit the requirements of the devices that they are required to drive.

Layout of Outputs Section

The output set-up options are listed in the output section.

Figure 16 Outputs layout

As with the inputs, the pin number of the output precedes the output name. Likewise, this is particularly handy
for quick fault finding and testing when required.
The configuration of the outputs can be changed using the following two methods;
 Method 1
Click next to the output which will display each setting one line at a time (refer to Figure 16 above).
Clicking the current setting will display a listing on the screen showing the options for that setting.
 Method 2
A quicker way for experienced users to change an output’s setting by clicking on the icons to the right of
the output name. These icons also serve as a quick visual indication of the state of the output.

Output Configuration
All lube controllers have the following output settings:
Setting Description
Active Mode Active Normal means that the device outputs’ supply voltage when the output is active.
Active Inverted means that the lube controller outputs’ supply voltage when the output is
inactive (i.e. the output is inverted).
Active Tells the user whether the output is currently active (on) or inactive (off) (this cannot be
edited and hence is greyed out).
Enabled When true the output is enabled. When false the output is disabled (i.e. ignored).

On-Board Indicators and Output Options

Lube controllers have six on-board indicators and an audible alarm (Sonalert).

Figure 17 LEDs section

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 ■ State
Each of the on-board indicators can be enabled and disabled either through the expanded listing or by
summary listing. The current state of the indicators is displayed in the same way that the inputs and outputs
display an active input/output.

■ Indicator Brightness Calibration

The indicator brightness can be modified by adjusting the corresponding brightness value. The lube
controller allows the user to adjust the brightness of individual colours.

■ Lamp Test Period

At power-up, all of the on-board indicators and the on-board audible alarm (if enabled) turn on to indicate
that they function correctly. The lamp test period can be adjusted using the software, however RCT advises
that this should not be changed.

■ Sonalert Level
The Sonalert level value can be adjusted in the software to change the sound level of the on-board audible
alarm.

Testing and Simulation

Testing a Physical Lube Controller
When a physical lube controller is connected, it can be tested using the software to control some or all of the
inputs. Inputs, outputs and on-board indicators can all be overridden and forced to be either on or off via the
software. This allows the user to simulate real inputs and hence run the device for testing.
To override an input, output, or indicator, click the active icon in the summary listing next to the
input/output/indicator. An orange circle icon appears in the enabled position to indicate that
input/output/indicator is overridden. Clicking on the active icon causes the input/output/indicator to toggle
between on (dark green) and off (dark red). Clicking on the override icon will remove the override on the
respective input/output/indicator.
Referring to Figure 18 below is an example showing two inputs being overridden. Pressure switch 1 is being
overridden showing the input as on while pressure switch 2 is being overridden showing the input as off.

Figure 18 Override example

Running a Simulation
When a lube controller is simulated, it is possible to run a simulation of how that lube controller would perform
if the current settings profile were to be loaded into a physical device working out in the field.
To run a simulation, simply click on the play icon in the toolbar at the top right-hand corner of the window. The
simulation speed can be increased by clicking the fast-forward icon in the toolbar. The simulation can also be
paused by pressing the pause button on the toolbar. Press the play icon to return the simulation to normal
speed after pausing or speeding it up.
When running a simulation, the Muirhead® Lube Controller software automatically overrides all inputs. Then
the user must control the inputs to the desired states. The lube controller software will simulate how the lube
controller would operate out in the field.

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 Factory Default Settings
Lubrication Options

Lubrication bank configuration Single

Pump output type Continuous and pulsed
Pressure sensors fitted Yes
Lube on power up No
Externally mounted lubrication button No

Timer Settings
Pause time 15 minutes
Lubrication time 2 minutes

Alarm Options
Low grease level alarm Continuous
Alarm mute period 10 minutes

Advanced Settings

Activate low grease level output No

Enable pump lockout after set number of open failures Yes
Number of open failures before pump lockout 2

Service Information
Service Schedule
The manufacturer recommends that the following service procedure should be performed at each machine’s
scheduled service interval.

Service Procedure
1. Perform a visual inspection; include the following:
a) Control unit.
b) Wiring connections and looms.
c) Check that all switches and solenoids are in good working condition.
2. Perform a system test as per the following:
a) Refer to the Operation and Use section of this manual for instructions on the operation of each function.

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 Parts List
The following table lists parts that are supplied with the programmable lubrication (lube) controller.
Part No. Description
9252 Programmable Lube Controller

The following parts are required when programming the 9252 lube controller.
The kits listed below are not included with the lube controller and must be purchased separately.
Part No. Description Qty
11199 Kit Programming Lube Controller (9252) 1
■ 3314 Programming Loom
■ 10492 In-line Programming Loom to Suit 9252
■ 11194 Lube Controller Software Program
12076 Kit Adaptor USB-to-Serial 1
■ 2694 USB-to-Serial Adaptor
■ 12077 Software for 2694 Adaptor

Technical Specifications
Dimensions, control unit only: Length: 84 mm | Width: 65 mm | Height/Depth: 47 mm
Dimensions, boxed for freight: Length: 155 mm | Width: 95 mm | Height/Depth: 75 mm
Weight, control unit only: 0.165 kg
Weight, including harness /
0.25 kg
packaging for freight:
Input nominal voltage: 12 to 24 V
Operating temperate range: 0 to 70 °C
Connection types: 12-pin Deutsch receptacle
Inputs: Switch inputs, battery supply, ground
Min & max input voltage: 8 to 36 Vdc
Enclosure type: Delrin machined enclosure
Environmental protection IP rating: IP44
Programming/adjustment: Yes

Compliance and Standards

TBA

Troubleshooting
Fault Possible Cause
Device not working. Check wiring and connections.
Intermittent fault. Check wiring and connections.

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 Glossary

A Amp (Ampere) MIN Minimum

ac alternating current mm millimetres
AMS Advanced Management System mW Milliwatts
Aux Auxiliary Output N/A Not Applicable
CAN Controller Area Network N/C Normally Closed
®
CMIO ControlMaster Input Output PCB N/O Normally Open
®
CMR ControlMaster Receiver OEM Original Equipment Manufacturer
CMT ControlMaster® Transmitter O/P Outputs
®
CM2200 ControlMaster 2200 Remote Set Out Output
COMMS Communications PB Push Button
CPU Central Processor Unit PC Personal Computer
dc direct current PCB Printed Circuit Board
E.G. For example PIN Personal Identification Number
ETR Energised To Run PLC Programmable Logic Controller
ETS Energised To Stop POT Potentiometer
ESD Engine Shutdown PPM Pulses Per Metre
FET Field Effect Transistor PWM Pulse Width Modulation
GND Ground PWR Power
H Hours Rev Revision
HEX Hexadecimal Numbering System RF Radio Frequency
ID Identity RH Relative Humidity
i.e that is rpm Revolutions per minute
In Input RX Receiver
Recommended Standard (number 232)
IP Ingress Protection RS232
for serial data transfer
kg Kilogram SYS System
Km/h Kilometres Per Hour TOV Text On Video
LCD Liquid Crystal Display TX Transmitter
LED Light Emitting Diode USB Universal Serial Bus
LK Link V Volts
M Minutes °C Degrees Centigrade
mA Milliamps # Number
MAX Maximum < Less Than
MCU Multi-Control Unit > Greater Than
MFU Multi-Function Unit % Percentage
Mega Hertz (million(s) cycles per
MHz
second)

Warranty
Please see the RCT standard warranty, available on our website - www.rct-global.com.

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 Revision History
Rev Date By Details of change
1.0 08/07/2011 BT Initial document draft and approval
1.1 12/10/2015 GT Updated Operation and Use, Installation Guide and Calibration sections
1.2 25/10/2016 CC Updated Company Contact information.
1.3 27/03/2018 JunW Updated all screenshots.
1.4 05/04/2018 JunW Updated drawing 423a
1.5 12/11/2018 CC Updated manual format – added Revision History section.

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 Discover more: www.rct-global.com

sales@rct-global.com

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