ER-105.1.

1 ECN: 201801325 VER: 4 - 11-19-2018

Proflo Lubricator Fluid-Flow Monitor/No-Flow

Timer Switch
CAUTION: Any arc welding on the skid and/or associated equipment and piping can per-
manently damage solid-state electronic equipment. Welding can cause immediate failure or
reduce electronic equipment life and void the warranty. To protect electronic equipment
prior to any arc welding (including repair welding), disconnect all electrical connections
including ground, and remove batteries, or completely remove the electronic equipment
from the compressor.

It is good practice to attach the welding ground clamp as close as possible to the area
where the welding will occur and to use the lowest practical welder output setting. Welding
must not cause a current flow across any compressor bearing surface, including but not lim-
ited to crankshaft and crosshead bearing surfaces.

The battery-powered, programmable

Proflo is an electronic microprocessor- 1. Hex-Socket Set
based switch that senses slow-flow or Screws (2)
no-flow conditions in the compressor cyl- 2. Magnetic Pin Housing
inder force feed lubrication system to (attaches to divider
facilitate alarm and/or shutdown. It eases valve)
force feed lube system operation by 3. Liquid Crystal Display
accurately monitoring cycle time and sys- (LCD)
tem performance. Operators use this 4. Infrared Wireless
information to optimize force feed lube Connection IrDA Port
and reduce operating costs. (to download data to a
hand-held computer)
The Proflo monitor works through a mag-
5. Set Button
netic pin that cycles back and forth as the
6. Mode Button
divider valve piston moves. The mag-
netic pin housing normally threads into
the divider valve. The monitor box hous- FIGURE 1 Proflo Electronic Lubricator Fluid Flow Monitor and
ing slides onto the pin housing and two No-Flow Timer Switch
hex-socket set screws hold it in place.
The liquid crystal display (LCD) indic-
ates:
1. Total operating time of the force feed lube system in hours.
2. "Average", "Last" and "Current" cycle time of the divider valve in seconds.
3. Total divider valve cycles.
4. Remaining battery life in percent.
5. Alarm set time for no-flow indication (programmable from 30 to 240 seconds).
6. Alarm wiring mode: Normally Open or Normally Closed.

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Proflo electronics come with reverse polarity protection/correction that automatically corrects a reverse
polarity output connection on both pulse and alarm outputs.

Normally Open and Normally Closed Definition

Most electrical components define Normally Open (NO) and Normally Closed (NC) operation as the default
state or “on the shelf” state. Example: A NO solenoid valve is open when the coil is not energized, and
closed when the coil is energized. A NC solenoid valve is closed when the coil is not energized, and open
when the coil is energized. This is not true of DNFT or Proflo electrical contacts. Both the DNFT and Proflo
switch contacts are defined as switch states after the divider valve cycles.
NO = Normally Open when running; switch is open while the divider valve cycles. This is non-fail-safe oper-
ation. If a wire falls off while the unit runs, the control system will not alarm/shutdown.
NC= Normally Closed when running; switch is closed while the divider valve cycles. This is fail-safe oper-
ation. If a wire falls off while the unit runs, the control system will alarm/shutdown.
Ariel recommends NC operation.The Proflo is pre-programmed for NC operation.

Proflo Installation
1. Loosen the two hex-socket set screws on top of
Proflo case and remove magnet housing. Do not
remove magnet, spring, and spacer from
magnet housing.
2. Remove end plug from desired divider valve.
The Proflo installs on either side of any divider
valve, but requires the correct magnet housing
for each divider valve manufacturer (Trabon,
Lincoln). NOTE: Do not install the Proflo on
any divider valves with cycle indicator pins.
3. Verify O-ring is in place on Proflo magnet
housing. Screw magnet housing into end of 1. End Plug 5. Hex-Socket Set Screws (2)
divider valve. Torque magnet housing to 15 foot- 2. Divider Valve 6. LCD Display
pounds max. 3. Magnet Housing 7. Wire Leads
4. Slide Proflo all the way onto magnet housing. 4. O-Ring
Torque set screws to 15 inch-pounds max. DO FIGURE 2 Typical Proflo Installation
NOT over tighten set screws.
5. The Proflo LCD indicates cycle time. Verify correct operation by pumping oil through the divider valve
assembly. The LCD enables the operator to adjust the lubricator pump for correct cycle time. The force
feed lubricator data plate on the lubricator box indicates either normal and break-in cycle times at
maximum rated speed, or normal cycle time for applied speed. Use break-in cycle times only for the first
200 hours of operation before changing to the normal cycle time. If unable to determine cycle time,
contact the Ariel Response Center.
6. All conduit and connections should be appropriate for area classification. Use flexible conduit to ease
installation. Support conduit and fittings to minimize vibration.
7. After Proflo installation or performance of any maintenance on the lube system, compressor cylinders, or
packing, pre-lube the complete system with a purge pump to purge air from the divider valves
and all components BEFORE COMPRESSOR START-UP.

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Proflo Button Operation
1. Push SET button to clear ALARM. When the LCD displays LASTand AVG, the alarm output contact
enters the “as running” state; set operation to NC to close the output alarm contact. LAST is the last
divider valve cycle time in seconds. AVG is the average time of the last six (6) divider valve cycles in
seconds.
2. Push MODE button; the LCD displays NOW, which is current divider valve cycle time in seconds. This
mode allows operators to accurately change cycle time by adjusting the force feed lubricator pump. The
force feed lubricator data plate on the lubricator box indicates either normal and break-in cycle times at
maximum rated speed, or normal cycle time for applied speed. Use break-in cycle times only for the first
200 hours of operation before changing to the normal cycle time. Compressor speed is directly
proportional to cycle time; at 50% rated speed, the lube cycle time doubles (see lube sheets in the Ariel
Parts Book for table of speeds vs. cycle times). If unable to determine cycle time, contact the Ariel
Response Center.
3. Push MODE button again; the LCD displays RUN TIME, which is the total run time of the lube system in
hours since the last reset.
4. Push MODE button a third time; the LCD displays CYCLE TOTAL, which is the total divider valve cycles
since the last reset. Test Proflo for reliability if CYCLE TOTAL displays over two million.
5. Push MODE button a fourth time; the LCD displays BATTERY - PCNT, which indicates percentage of
remaining battery life. If battery voltage drops below safe operating levels the monitor enters ALARM
mode.
6. The display mode changes to ALARM when an alarm is triggered. The display defaults to LAST and
AVG while the divider valve cycles. To set alarm time and mode:
a. Push SET.
b. Push MODE six times until LCD displays SETUP?.
c. Push SET. The LCD displays SET ALARM TIME.
d. Push SET again to display current alarm time.
e. Push and release SET button to change alarm-shutdown from 30 to 240 seconds in 5 second
increments. Ariel typically sets it to 120 seconds. Ariel recommends setting alarm time to 2 times
normal cycle time rounded up to the nearest 5 seconds. Minimum: 30 seconds; maximum
180 seconds. Find normal cycle time on the force feed lubricator data plate.
f. Push MODE two more times to scroll the LCD to SET ALARM MODE, which configures the control
system to shutdown the compressor for a no-flow indication. Push SET to toggle from N/O (normally
open) or N/C (normally closed). Ariel recommends N/C operation. After setting wiring mode,
either push MODE two times or simply wait 30 seconds to return to the LAST and AVG display. The
Proflo records any setup changes to the EEPROM.

Display Errors
ALARM - Displays when divider valves are not cycling. Programmed divider valve cycle time has expired.
ALARM flashes every 2 seconds during compressor shutdown.To clear alarm, press SET. Alarm will clear
and again indicate cycle time upon compressor re-start.
OVERLOAD - Indicates a wiring short or circuit switching of too large a load. To correct this, check wiring
insulation for bare wires touching ground or each other. Insulate unused wires or re-terminate wires. Self-
resetting fuses on the inputs protect Proflo electronics; they auto reset 45 seconds after fixing a short.

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LOW BATT - Indicates 20% remaining battery life. At 10% remaining battery life, the Proflo shuts down the
compressor and flashes ALARM and LOW BATT until batteries are replaced. See battery replacement pro-
cedure below.
RESET X - Indicates an internal Proflo fault. No alarm displays; the Proflo still counts divider valve cycles
and controls inputs and outputs. While the divider valve cycles, the Proflo counts pulses and measures time
between divider valve cycles. At 30-minute intervals, the processor writes data stored in memory to on-
board EEPROMS. If there is a problem with this, the Proflo issues a Reset error.
1. RESET 1 - Proflo processor unable to determine if the EEPROM contains valid configuration
information. Reset 1 usually occurs after a RESET 3 occurs. Upon reboot, the Proflo loses stored and
configuration data; programmed information must be re-entered.
2. RESET 2 - Proflo processor unable to determine storage of any data or location for next data. Upon
reboot, the Proflo loses stored data, but retains configuration data; programmed information need not be
re-entered.
3. RESET 3 - Internal Proflo fault. The Proflo processor tried and failed three resets. The most likely cause
is failure to write to the EEPROM. To try to correct the problem:
a. Remove Proflo batteries.
b. Press SET button for 45 seconds to discharge internal capacitors and ensure a complete reset.
c. Re-insert batteries to reboot the Proflo.
l If the error was a one-time problem, the Proflo reboots as normal.
l If diagnostics detect an error on reboot, the Proflo displays a constant RESET error again. Replace
the Proflo and contact Ariel Corporation. Sometimes on reboot, the Proflo flashes RESET. This is
normal.

NOTE: Moisture on Proflo circuitry causes most reset errors. Several design precautions keep
moisture from the circuit board:
l The Proflo housing is completely sealed in a low humidity room.
l There is a desiccant pack in the circuit board chamber.
l The circuit boards have a protective conformal coating.

Downloading Proflo Data

Use a hand-held palm operating system computer equipped with an infrared (IrDA) port and running Palm
Operating System to interface with the Proflo. Use Fluid Flow Trending (FFT) software to download oper-
ating data. This feature is not essential for compressor operation, but recommended to evaluate force feed
lube operation and reduce operating costs. Contact Ariel for details on FFT software. FFT software can
provide the following information:
1. Oil consumption for each 30-minute interval of compressor operation.
2. Days of over and under lubrication.
3. Total oil consumption of compressor lube system
4. Daily and total lost dollars (US) for over-lubrication.

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5. Total divider valve cycles.
6. Total compressor run time.

The Proflo monitor stores up to one year of operating data in first in, first out (FIFO) memory. FFT software
can reset Proflo memory. Reset time and date records to the Proflo Electrical Erasable Programmable
Read Only Memory (EEPROM).
To start the download, push SET then push MODE five times until the LCD displays SEND DATA?, then
push SET again. Set the FFT software to accept the Proflo data and hold the handheld computer in a pos-
ition to communicate with the IrDA port. The LCD displays SENDING. If there is no device to receive data,
the LCD displays FAILURE and returns to LAST and AVG default display after 30 seconds. The software
converts Proflo data to Microsoft Excel files for trending and graphing.
The internet or most electronic and discount stores offer hand-held palm operating system computers. For
more details on this and other Proflo accessories, contact your packager or Ariel.

Proflo Battery Replacement

The Proflo formerly used alkaline batteries. Sometimes, alkaline batteries leak, release acid, and corrode
the battery compartment, and their service potential diminishes at extreme temperatures. The Proflo now
uses Lithium batteries, which provide superior leakage resistance, greater service advantage at tem-
perature extremes, and longer shelf and service life. Ariel highly recommends AA Energizer Lithium/FeS2,
model L91 batteries to reduce maintenance costs. This is a true Lithium battery, unlike several other brands.
While not recommended, use replacement alkaline batteries only when Lithium batteries are unavailable.
Component damage due to battery leakage is not normally covered under warranty. Front cover removal
voids the warranty, except on older Proflo monitors made prior to 3/2003 where batteries may be located
under the front cover.

CAUTION: EXPLOSION HAZARD! Disconnect/lockout electrical power to control circuits

before battery cover removal. Power connected to the Proflo presents a potential of fire,
electrical shock, personal injury, or death. Change batteries only in a non-hazardous area.
Earlier Proflo models use a front battery access cover while later models use a rear access
cover to reduce potential risk. Disconnect power to Proflo to replace batteries regardless of
battery access location.

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1. Remove the six battery cover screws.
2. Remove battery cover and gasket.
3. Remove old batteries. Remove plastic protective sleeves from old
batteries. Save the sleeves and discard the old batteries in a
responsible manner.
4. Press SET for 45-60 seconds without batteries installed to dissipate
stored energy and allow the battery display to update immediately
after new battery installation. This step is optional; the monitor
automatically updates the battery display within 30 minutes of
operation.
5. The outer cover of batteries is the positive terminal; verify it is
unscratched. If a scratched outer cover touches the metal battery
holder, the battery depletes very quickly and the Proflo displays LOW
1. Battery compartment cover
BATT. It is possible for one battery to completely deplete and the with gasket
other to reverse polarity. Replace with new unscratched batteries if
2. AA Energizer lithium L91
this occurs. batteries with plastic sleeves
6. Slide the plastic protective sleeves onto the new batteries and insert 3. Battery cover screw
new batteries into the battery holder. The plastic sleeves and the 4. Battery clips
gasket on the bottom of the cover ensure a tight battery fit. FIGURE 3 Proflo Rear Battery
Compressor vibration can cause premature failure in batteries not Compartment
installed tightly. Verify the batteries are installed with correct
negative/positive orientation. Do not scratch or damage new battery
outer covers during installation.
7. Re-assemble cover, gasket, and screws. The cover holes align with the six monitor body holes in only
one direction; verify correct installation. Installing the cover upside down results in stripped screw threads
and compromises the battery compartment seal. Do not over-tighten the screws. Replace lost cover
screws with 4-40 x 3/16 in. pan head machine screws.
8. Press SET once, then press MODE until the LCD displays BATTERY. If stored energy was dissipated
(see step 4), the monitor checks battery voltage, resets, and displays remaining battery power. The
monitor automatically searches for battery voltage at the next 30 minute read/write interval and updates
to the new battery power percentage. All trending and configuration data store in the Proflo EEPROM.
Battery failure or replacement causes no memory loss.

Proflo Wire Identification and Electronic Indication

Instructions
NOTE: To use pulse output (blue wires) and alarm circuit (red wires) simultaneously, see "Using
Pulse Output and Alarm Circuit Simultaneously".
Blue Wires: Pulse output. Use the two blue wires to send a transistor pulse output for each divider valve
cycle to a PLC (Programmable Logic Controller), Scada System, Digital Counter, or Digital Control Panel.
Maximum switching load is 36 VDC @ 500mA. Insulate blue wire ends from each other and conduit
or compressor ground when not in use. Pulse duration is 500 milliseconds. Switch output operation:
Pulse represents one divider valve cycle or period.
White Wires: Switch input. Remote mounting Proflo display. Connect the two white wires to a dry
contact proximity switch to remotely mount the monitor box housing in a convenient location on the com-
pressor frame or in the control panel. Ariel recommends distance between proximity switch and the panel

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mounted Proflo not exceed 600 feet (183 m). See "Operation Notes" for details. Insulate white wire ends
from each other and from ground when not in use. Call Ariel for information about a panel mount kit.
Red Wires: Alarm switch output. Use the two red wires for alarm or shutdown no-flow indication at a con-
trol panel. When the divider valve cycles, this contact closes in Normally Closed (NC) operation and opens
in Normally Open (NO) operation. The contact returns to static state when the preset timer times out. Switch-
ing Capacity: 36 VDC @ 500 mA max. Insulate red wire ends from each other and from ground
when not in use. This output operation is programmable as NO or NC. Ariel recommends a NC system for
fail-safe operation. Red wires are not polarity sensitive. See "Normally Open and Normally Closed Defin-
ition".
Green Wire: Always secure green ground wire to "earth ground" in the control panel. Do not ground to the
electrical conduit. Improper grounding can result in unreliable monitor operation.
NOTE: To switch to 120/240 VAC load using Proflo outputs, ask Ariel about a relay interface.

Using Pulse Output and Alarm Circuit Simultaneously

If the control system must read block cycling, proximity switch, and alarm contact, consider this:
1. The Proflo on-board processor and data acquisition system (DAQ) records the time for each divider
valve cycle and stores this data to EEPROM. A Palm Operating System hand-held computer with FFT
software can download this data through the Proflo infrared port so the control system need not read and
count divider valve cycles.
2. If a PLC reads pulse output, users may program it to watch divider valve cycling and issue a shutdown if
the block fails to cycle for a given time. This may eliminate the need to wire to both Proflo outputs and
save on field wiring connections.
3. The Proflo alarm output red wires and the divider valve cycle output blue wires are not isolated from each
other. If it is necessary to read both Proflo outputs, isolate the equipment that reads the contacts. If the
PLC input card is not isolated between channels, both the alarm and pulse outputs act as the alarm
contact. Isolate these contacts from other inputs. See FIGURE 4.

FIGURE 4 Example Diagram to Read both Pulse and Alarm Contacts

4. If isolated inputs are not an option, connect the alarm/shutdown contact to the safety system and install
another proximity switch for the control system to read and calculate oil consumption. Contact Ariel for a
proximity switch part number.

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5. If isolated PLC inputs are not an option, wire the Proflo to the "coil" side of a relay, and the control system
to the contact side of the relay. There are inexpensive relays on the market. Ariel recommends a solid-
state relay for long life. See FIGURE 5.

FIGURE 5 Example Diagram to Read both Pulse and Alarm Contacts

Some relays may require a current limiting resistor to prevent shorting the power supply through the relay
coil. Many relays come with built-in current limiting circuits. The control system designer must choose proper
relay components.

Using a PLC to Calculate Oil Consumption

Use the Proflo pulse output (blue wires), the control system can calculate TABLE 1 Example Divider
system oil consumption. For example: Valve
0.144 x 0.0346 = 0.004987 pints/cycle Block # In3 x2
l The first number is based on block numbers, which are stamped into 12T 0.012 0.024
each block of a compressor divider valve. Divide a block number by
1000 to obtain the volume in cubic inches. Multiply this volume by 2 to 18T 0.018 0.036
obtain the full volume for one full cycle. Do this for all the blocks in the 18T 0.018 0.036
divider valve, then add them together. See TABLE 1.
6S 0.006 0.012
l 0.0346 converts cubic inches to pints (US liquid).
18T 0.018 0.036
l For gallons (US liquid), divide pints by 8.
TOTAL 0.144
l For liters, multiply gallons (US liquid) by 3.78541, or multiply pints (US
liquid) by 0.47318.

Enter the above calculation as a constant for each Proflo. In the example, the PLC calculates a running total
by adding 0.004987 pints to a totalizer the whole time the compressor runs. Use this information to track oil
consumption.

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Operation Notes
1. If alarm output is set to NC operation and the batteries are removed or die, the Proflo opens the alarm
contact. If alarm output is set to NO operation and the batteries are removed or die, the alarm contact
remains open, and the control system will not alarm. For this reason, Ariel recommends NC contact
operation.
2. Proflo default programmable settings as delivered to Ariel or reset with the FFT software:
l Alarm trip time = 120 seconds
l NC/NO settings = NO or non-fail safe
Ariel shop work instructions set outputs to:
l Alarm trip time = 120 seconds
l NC/NO settings = NC or fail-safe
See "Normally Open and Normally Closed Definition" and "Proflo Button Operation".
3. Remote mounted Proflo and proximity switch. The Proflo excites the proximity switch circuit with 3-
volt battery power to detect the proximity switch state. Ariel defines maximum wire distance between the
proximity switch and the remote mounted Proflo as 600 feet (183 m) using standard Proflo batteries, and
10,000 feet (3050 m) powering the Proflo from another power source. Ariel conservatively calculated
these distances based on the following assumptions:
a. Standard 22 gauge instrumentation wire at 68°F (20°C) in a continuous run.
b. Non-significant battery life degradation.
c. No electrical noise injected into wire run.
For a panel-mounted Proflo, Ariel recommends users remove the batteries and use a CCT power sup-
ply.
4. The Proflo records any setup changes to the EEPROM.
5. The white wires on the Proflo can be used for other applications besides reading divider valve cycle
times. The Proflo records history for any dry contact switch such as a liquid dump valve, high-
temperature switch, or valve limit switch.
6. Proflo electronics come with reverse polarity protection/correction. The electronics automatically correct
a reverse polarity output connection on both pulse and alarm outputs.

Proflo Specifications
l Temperature Range: -40°F to +185
l Switching Capability: 170 VDC - 120 VAC @ .5 Amps
l Environment Rating: Class I Div. 2 Groups A,B,C,D - T4
l Internal Power: AA Lithium batteries.
l Device Inputs: Remote switch closure from proximity switch to enable operator to mount Proflo in a
control panel, control room, or other location.

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 l Device Outputs: Pulse output with each divider valve cycle.
l Alarm Wiring: N/O (Normally Open) - N/C (Normally Closed).

Proflo Accessories
1. AC panel mount power supply - for safe area only.
2. Panel mount kit. Includes panel mount bracket and a proximity switch.
3. Relay interface module. Use to switch an AC load 120/240 VAC @ 10 Amps.
4. Additional proximity switch.
5. Palm interface Fluid Flow Trending (FFT) software. Converts all information to Excel format for hard
copy trending, graphing, and presentation:

l Oil consumption for each 30 minutes of compressor operation.

l Every day of over and under lubrication.
l Total oil consumption of the compressor lube system.
l Daily and total lost dollars due to over lubrication.
l Total divider valve system cycles.
l Total compressor run time.

For more details on the Proflo and available accessories, contact your packager or Ariel.

The contents of this document are proprietary and confidential. They are the property of Ariel Corporation and may
not be disclosed, reproduced, or used for manufacture in part or in whole without written permission from Ariel Cor-
poration.

DATE: VER: ECN: DESCRIPTION:

11-19-2018 4 201801325 Page 2, “Proflo Installation”, #7: “purge pump” WAS “purge gun”. Transferred document to
responsive design.

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