Milacron Powerline 330 auto lube failure

I have a 2001 Powerline 330 that has locked itself out with an auto lube failure.
The reservoir has grease, the system is pressurized at 20 psi & the limit switch on the clamp side is working [light 8 on module 4]
I can't clear the alarm???

Error code #?
Lube pumps tend to to fail when there’s air in the system.
Try purging the air from the grade lines.

I didn't see an error code?
Just .... Auto Lube Failed - Cycle Inhibit

Purge the air from the lines, locate some plugs on the manifolds of the grease lines and open them, after that manually pump grease with your machine controller. If you can’t find any plugs just disconnect any grease line from the grease manifolds and turn ON your pump to purge the air.
That should do the work.

Let me know what solution works for you! I believe some operators here had the same issue. I will ask them next week if they ever resolved the issue.

I copied the Lube System troubleshooting guide for you to reference. This should get you out of trouble. I had to post it in two parts

System Overview
The Trabon Lubrication System is the feeder network. The feeder is self-cycling and is made up of three or more working sections, which contain metering pistons. The pistons move in a defined sequence and each stroke of a piston displaces a measured amount of lubricant to another divider valve (secondary), or to a lubrication point. As a given piston completes its stroke, it redirects pump flow to the next piston in the sequence (Series Progressive).
One piston in the master divider is equipped with a cycle indicator pin that actuates a cycle/limit switch. One in-out-in motion of this pin (two switch transitions) signals a complete cycle of the master divider to the machine controller. If the two switch transitions are not received within the programmed monitor period (usually 75 seconds) an “Auto Lube Failed” Message will be displayed on the controller screen and the source of the problem should be corrected as soon as possible. If the cycle switch signal is received before expiration of the monitor period, the cycle has been successfully completed, the system pump will shut down and the controller will begin its countdown to the next scheduled lube occurrence.








The system is made up of a pump and the feeders. As long as flow is applied to the feeders, they will divide the lubricant. The master feeder, or first feeder in the system, receives the full flow from the pump and divides this flow to the secondary feeders. The secondary feeders then re-divide the lubricant and distribute it to the bearing points. The actual amount of lubricant displaced to each outlet during each cycle of the feeder will depend on the diameter of the piston serving that outlet. How the total flow to the feeder is divided will depend on the size of the pistons in each working section and the number of working sections.
There is a number and a letter stamped on each working section. The number is the output (for each piston stroke) of that working section per cycle of the feeder in thousandths of a cubic inch. The letter S or T indicates single or twin outlets. An S working section is designed to discharge lube to only one point. The T working section, or twin must have two lines and discharge lubricant to two points, or the divider will lock.
Page 1
Since a singled outlet receives two strokes per valve cycle, its output is double that of a twin outlet.
Lubricant level in the clear plastic reservoir can be visually observed and a routine replenishing schedule should be established so that the reservoir level never drops below one inch of grease. This is necessary in order that the system pump not become air bound, or expels air into the system. The reservoir is also equipped with a low level switch that will signal an ”A2 Lube Level Low” message on the controller screen. When this message is displayed, the replenishing schedule has not been followed, the pump has been manually cycled an excess number of times, or there is a leak in the system. In any case, the reservoir should be promptly refilled and the cause of the alarm corrected.

Part2
Lube System Warning and Malfunction Indicators

There are two electronic warning indicators of system malfunction and five visual indicators. Alone, or in combination, they can greatly simplify the job of troubleshooting the system.
Electrical: • “Auto Lube Failed” message ) Both of these start a sequence in the • “Lube Level Low” warning message ) machine controller that will result in an auto shutdown if not corrected.
Visual: • Reservoir Grease Level (height of follower seal/grease level can be seen through clear plastic reservoir tube). • System Pressure Gauge (can indicate current, or impending problems due to either low, or high pressure). • Pump High Pressure Rupture Assembly (disc will rupture as a result of high pressure/blockage in the system that is down stream of the pump). • Master Divider Cycle Indicator (pin moves in and out with displacing piston in response to pump flow as it actuates the cycle switch). • Master Divider High Pressure (Reset) Indicators (Extend due to high pressure/blockage that is down stream of the output section to which they are attached).


Lube System Troubleshooting
“Auto Lube Failed” message on controller screen - The master divider cycle/limit switch signal was not received within the programmed monitor time (usually 75 seconds). The problem could be mechanical, or electrical.
Mechanical causes: Pump won’t build pressure (pump rupture disc blown due to blockage in system, possible air bound pump, defective pump, or gear motor, cut hose between pump and master divider).

Page 2
• Check pump rupture disc assembly for exit of grease. If ruptured, locate blockage in system. Note, if a Reset Indicator pin on the Master Divider is extended, the blockage is down stream and is in the connected Master to Secondary hose, within the Secondary Divider, or within one of its connected lube points. If the Reset Indicator pin is not extended, the blockage is within the Master Divider, or the pumps to Master supply hose (Refer to Lubriquip Bulletin 30101 for how to locate blockage).
If severe contamination is suspected, or if separated soap (hard waxy substance) is found in divider passages, the entire system will require cleaning and purging and in some cases, the divider valves may need to be replaced. If soap separation is the problem, the choice of grease should also be reviewed with the lubricant supplier.
Repair or replace source of blockage being sure to purge any new or removed components with fresh clean grease that is free of air before connecting them to downstream lines.

• If rupture disc is not blown, check pump for operation (should be able to hear pump motor and see pressure fluctuation on gauge).

• If pump motor is running and pump will not build pressure, most likely the pump has become air bound due to allowing reservoir level to drop too low, or air has been pumped into the reservoir during the grease replenishing operation.
IF the former, the pump and possibly the Master Divider supply hose will need to be purged of air and the replenish interval should be reviewed.
If the latter, the reservoir contents will need to be emptied by opening the drain cock on the bottom right side of the reservoir after which it must be refilled with clean fresh grease that is free of air (refer to reservoir filling and pump purge procedure).

• If pump flow has diminished due to wear, the pump must be replaced.

• If there is power at the pump and the pump motor does not run, the pump is defective and must be replaced
Note: reservoir does not need to be emptied, or removed to change pump. The pump is held in place by four cap screws accessible from the bottom. Be sure to follow pump-purging procedure before connecting replacement pump to system.

• If the pump is producing flow and the rupture disc is not blown, check for a cut hose between pump and master. Replace as required being sure to pre-fill hose with fresh clean grease before connecting it to the Master Divider.
Electrical causes: Cycle switch bracket has moved back on indicator housing and as result, switch is not being actuated by indicator pin.

Part3 of 3

Page 3
• Check for cycle indicator movement at Master Divider and for bracket position on indicator housing. If indicator does not move in and out when pump operates, problem is mechanical rather than electrical (refer to mechanical causes). If bracket has moved on housing, reposition against stop and tighten clamp screw.
Defective cycle switch. • Actuate switch manually and check for cycle input at controller screen. If there is no input at controller, test switch with a continuity tester and replace if defective; or if switch is good, proceed to test for broken or shorted switch leads.
Broken, or shorted wire between cycle switch and controller. • Disconnect switch leads at Controller and simulate switch input with a momentary contact switch. Repair or replace defective leads.
If Controller does not respond to switch input, problem is in Controller, which must be repaired.
Monitor period too short (should be at least 2x the actual pump run time required to complete a lube cycle). • Increase monitor period to 2x actual pump run time required to complete cycle.
No power to pump (no power from controller, or broken wire). • Replace or repair defective wiring.

• Repair Controller.
“Lube Level Low” message on controller screen-The reservoir level switch contacts have transferred indicating low level. • Replenish reservoir with fresh clean grease that is free of air.

• Review and shorten replenishing interval so that grease level does not drop below 1” in the reservoir. • If reservoir level is not low, check switch operation with a continuity tester and replace switch if defective.

• If the switch is not defective, check the wiring for breaks, or shorts and repair as required.

Thanks Bryan.
Turns out the limit switch on the top of the clamp end had come loose from its bracket & was not getting the signal the line had pressurized.
Turned on the pump & cycled the switch a few times ... that cleared the cycle inhibit & reset the lube counter to zero.