Installation instructions. QLS 301 / QLS 401 Lubrication system. following machinery directive 2006/42/EC EN 2016/06/22 Version 07

Transcription

1 QLS 301 / QLS 401 Lubrication system Installation instructions following macinery directive 2006/42/EC /06/22 Version 07

2 EC Declaration of incorporation EC Declaration of incorporation following macinery directive 2006/42/EC, annex II, part 1 B Te manufacturer, SKF Lubrication Systems Germany GmbH, Walldorf Facilities, Heinric-Hertz-Str. 2-8, DE Walldorf, ereby declares tat te partly completed macinery Designation: Pump to supply lubricant during intermittent operation witin a centralized lubrication system Type: QLS 301 / QLS 401 Part number: P301XXXXXXXX / P401XXXXXXXX / 650-XXXXX-X Year of construction: See type identification plate complies wit te following basic safety and ealt requirements of te EC macinery directive 2006/42/EC at te time wen first being launced in te market Te special tecnical documents were prepared following Annex VII part B of tis directive. Upon justifiable request, tese special tecnical documents can be forwarded electronically to te respective national autorities. Te person empowered to assemble te tecnical documentation on bealf of te manufacturer is te ead of standardization. See manufacturer's address. Furtermore, te following directives and armonized standards were applied in te respective applicable areas: 2011/65/EU RoHS II 2014/30/EU Electromagnetic compatibility Industry 2006/28/EC Electromagnetic compatibility Automotive Standard Edition Standard Edition Standard Edition Standard Edition DIN ISO DIN DIN DIN DIN ISO DIN Amendment 2011 DIN DIN Amendment 2009 DIN Amendment 2010 DIN Amendment 2012 DIN ISO DIN Te partly completed macinery must not be put into service until te final macinery into wic it is to be incorporated as been declared in conformity wit te previsions of macinery directive 2006/42/EC and any oter applicable directives. Walldorf, 2016/20/04 Jürgen Kreutzkämper Manager R&D Germany SKF Lubrication Business Unit Stefan Scürmann Manager R&D Hockeneim/Walldorf SKF Lubrication Business Unit 2

3 Legal disclosure Legal disclosure Manufacturer SKF Lubrication Systems Germany GmbH Manufacturer's facilities Head Office Walldorf Facilities Heinric-Hertz-Str Walldorf Germany Pone +49 (0) Fax: +49 (0) Berlin Facilities Motzener Straße 35/ Berlin Germany Pone +49 (0) Fax +49 (0) Hockeneim Facilities 2. Industriestraße Hockeneim Germany Pone +49 (0) Fax +49 (0) Lubrication-germany@skf.com Training courses In order to provide a maximum of safety and economic viability, SKF carries out detailed training courses. It is recommended tat te training courses are attended. For more information please contact te respective SKF Service address. Copyrigt Copyrigt SKF. All rigts reserved. Warranty Te instructions do not contain any information on te warranty. Tis can be found in our general terms and conditions. Disclaimer Te manufacturer sall not be eld responsible for damages caused by: non appropriate use faulty assembly, operation, setting, maintenance, repair or accidents use of inappropriate lubricants improper or late response to malfunctions unautorized modifications of te product intent or negligence use of non-original SKF spare parts Liability for loss or damage resulting from te use of our products is limited to te maximum purcase price. Liability for consequential damages of watever kind is excluded. 3

4 Table of contents 1. Safety instructions General safety instructions General beaviour wen andling te product Qualified tecnical personnel Electric current azard System pressure azard Operation Assembly, maintenance, malfunctions, sutdown, disposal Intended use Foreseeable misuse Disclaimer of liability Referenced documents Residual risks Lubricants General information Selection of lubricants Approved lubricants Lubricants and te environment Lubricant azard Overview, functional description Described variants of te QLS system Mounting positions of te metering devices Canging te output volume of te SSV metering devices Canging te output volume of te SSVDV metering devices Return of unneeded lubricant to te pump Membrane keypad Displays in te display mode S4 control printed circuit board Displays in te programg mode S4 control printed circuit board Displays in te display mode S5 / S6 control printed circuit board Displays in te programg mode S5 / S6 control printed circuit board Table of contents 4. Tecnical data General tecnical data Electrics Factory settings of pumps wit S4 control printed circuit board Factory settings of pumps wit S5/ S6 control printed circuit boards Functioning principle of te intermittent low-level indication Operating limits of te intermittent low-level indication Processing of te low-level signals in case of external control and monitoring of te pump Tigtening torques Useable reservoir volume Lubricant requirement for prig of an empty pump Notes related to te type identification plate Notes related to te CE marking Type identification code QLS Type identification code QLS Type identification code QLS 401 SSVDV Delivery, returns, and storage Delivery Return Storage General notes related to storage Assembly General information Attacment Minimum assembly dimensions Connecting dimensions Electrical connection Prig of pumps witout follower plate

5 Table of contents 6.7 Prig of te QLS 301 wit follower plate Programg of control pcb S Programg of control printed circuit boards S5 and S Start-up General information Operation, sutdown and disposal General information Filling te reservoir during operation Temporary sutdown Sutdown and disposal Maintenance, cleaning and repair General information Maintenance Cleaning Replacement of te membrane keypad Troublesooting Spare parts SSV metering devices SSVDV metering devices Metering screws for SSVDV metering device Kit of seals Membrane keypad Pump element Adapter M22 x Indicator pin fitting Reservoir Housing cover replacement kit V DC motors motor connections VDC Electrical connections Housing cover replacement kit Circuit diagrams Legend Core assignment of te connection plugs Assignment of circuit diagrams to te pump Circuit diagram 12/ 24 V DC, wit square plug and control pcb S Circuit diagram 120 V AC, wit square plug and control pcb S Circuit diagram 230 V AC, wit square plug and control pcb S Circuit diagram 12/ 24 V DC, wit square plug witout control pcb Circuit diagram 12/ 24 V DC, wit bayonet plug and control pcb S Circuit diagram 230 V AC, wit square plug and cycle switc witout control pcb Circuit diagram 230 V AC, wit square plug witout cycle switc and witout control pcb Circuit diagram 120 V AC, wit square plug witout control pcb Circuit diagram 12/ 24 V DC, wit square plug and control pcb S6 (NO) Circuit diagram 12/ 24 V DC, wit square plug and control pcb S5 (NC) Circuit diagram 120 V AC (60 Hz), wit square plug and control pcb S6 (NO) Circuit diagram 230 V AC, wit square plug and control pcb S6 (NO) Circuit diagram 230 V AC, wit square plug and control pcb S5 (NC)

6 Explanation of symbols and signs Explanation of symbols and signs You will find tese symbols, wic warn of specific dangers to persons, material assets, or te environment, next to all safety instructions in tese operating instructions. Please read tese instructions torougly and eed te warning and safety notes. Please observe te warning and safety notes and exercise particular caution in tese cases. Inform also oter users accordingly. Symbols Symbol Meaning General warning Electrical component azard, electrical sock azard Warning level Consequence Probability DANGER Deat/ serious injury iment WARNING Deat/ serious injury possible CAUTION Minor injury possible NOTICE Property damage possible Slipping azard Hazard from ot surfaces Hazard from unintentional intake Crusing azard Pressure injection azard Wear personal protective equipment (goggles) Symbol Meaning Prompts an action Used for itemizing Refers to oter facts, causes, or consequences Provides additional information witin procedures Note Environmentally sound disposal recycling Environmentally sound disposal of waste electrical and electronic equipment 6

7 Explanation of symbols and signs Abbreviations and conversion factors re. regarding C degrees Celsius F degrees Fareneit approx. approximately K Kelvin Oz. Ounce i.e. tat is N Newton fl. oz. fluid ounce etc. et cetera our in. inc poss. possibly s second psi pounds per square inc if appl. if applicable d day sq.in. square inc a.a.r. as a rule Nm Newtonmeter cu. in. Cubic inc incl. including ml millilitre mp miles per our. imum ml/d millilitre per day rpm revolutions per ute max. maximum cc cubic centimetre gal. gallon. ute mm millimetre lb. pound etc. et cetera l litre p orse power e.g. for example db (A) Sound pressure level kp kilopound kw kilowatt > greater tan fpsec feet per second U Voltage < less tan Conversion factors R resistance ± plus/us Lengt 1 mm = in. I current Ø diametre Area 1 cm² = sq.in V volt kg kilogram Volume 1 ml = fl.oz. W watt r relative umidity 1 l = pints (US) AC alternating current approximately Mass 1 kg = lbs DC direct current = equal to 1 g = oz. A ampere % per cent Density 1 kg/cc = lb./gal(us) A Ampere our per mille 1 kg/cc = lb./cu.in. Hz Frequency [Hertz] greater tan Force 1 N = kp nc normally closed contact less tan Pressure 1 bar = 14.5 psi no normally open contact mm 2 square millimetre Temperature C = ( F-32) x 5/9 rpm -1 revolutions per ute Output 1 kw = p Acceleration 1 m/s² = ft./s² Speed 1 m/s = fpsec. 1 m/s = mp 7

8 1. Safety instructions 1. Safety instructions 1.1 General safety instructions Te owner must ensure tat safety information as been read by any persons entrusted wit works on te product or by tose persons wo supervise or instruct te before-mentioned group of persons. In addition, te owner must also ensure tat te relevant personnel are fully familiar wit and ave understood te contents of te Instructions. Te instructions must be kept at and togeter wit te product for future reference. Te Instructions are part of te product and must accompany te product wen selling it. Te described products were manufactured according to te state of te art. Risks may, owever, arise from its usage and may result in arm to persons or damage to material assets. Any malfunctions wic may affect safety must be remedied immediately. In addition to tese Instructions, general statutory regulations and oter regulations for accident prevention and environmental protection must be observed. 1.2 General beaviour wen andling te product Te product may be used only in awareness of te potential dangers, in proper tecnical condition, and according to te information in tese instructions. Tecnical personnel must familiarize temselves wit te functions and operation of te product. Te specified assembly and operating steps and teir sequences must be observed. Any unclear points regarding proper condition or correct assembly/ operation must be clarified. Operation is proibited until issues ave been clarified. Unautorized persons must be kept away. Precautionary operational measures and instructions for te respective work must be observed. Responsibilities for different activities must be clearly defined and observed. Uncertainty seriously endangers safety. Safety-related protective and emergency devices must not be removed, modified or affected oterwise in teir function and are to be cecked at regular intervals for completeness and function. If protective and safety equipment as to be dismantled, it must be reassembled immediately after finising te work, and ten cecked for correct function. Remedy occurring faults in te frame of responsibilities. Immediately inform your superior in te case of faults beyond your competence. Wear personal protective equipment always. Wen andling lubricants, adere to te respective safety data seets. 8

9 1. Safety instructions Qualiied tecnical personnel ly qualified tecnical personnel may install, operate, maintain, and repair te products described in tis document. Qualified tecnical personnel are persons wo ave been trained, assigned, and instructed by te operator of te final product. Suc persons are familiar wit te relevant standards, rules, accident prevention regulations, and assembly conditions as a result of teir training, experience, and instruction. Tey are qualified to carry out te required activities and in doing so recognize and avoid any potential azards. Te definition of qualified personnel and te proibition against employing non-qualified personnel are laid down in DIN VDE 0105 and IEC 364. Relevant country-specific definitions of qualified tecnical personnel apply for countries outside te scope of DIN VDE 0105 or IEC 364. Te core principles of tese country-specific qualification requirements for tecnical personnel cannot be below tose of te two standards mentioned above. Te operator of te final product is responsible for assigning tasks and areas of responsibility and for te responsibility and monitoring of te personnel. Tese areas must be precisely specified by te operator. Te personnel must be trained and instructed if tey do not possess te required knowledge. Product training can also be performed by SKF in excange for costs incurred. 9

10 1. Safety instructions 1.4 Electric current azard 1.5 System pressure azard 1.6 Operation WARNING Electric sock Working on products not disconnected from te power supply may cause personal injury and damage to property. Assembly, maintenance, and repair works may be performed by qualified and autorized personnel only on products previously disconnected from te power supply. WARNING System pressure Te product is pressurized during operation. It must be depressurized before starting assembly, maintenance, or repair works. Te following must be observed during commissioning and operation. All information witin tis manual and te information witin te referenced documents. All laws and regulations tat te operator must observe. Electrical connection may be carried out only by a qualified electrician autorized by te operator under consideration of te local connection conditions and legal prescriptions (e.g. VDE/ IEC). 10

11 1. Safety instructions Assembly, maintenance, malfunctions, sutdown, disposal 1.8 Intended use All relevant persons (e.g. operating personnel, supervisors) must be informed of te activity prior to starting any work. Precautionary operational measures and work instructions must be observed. Ensure troug suitable measures tat movable or detaced parts are immobilized during te work and tat no limbs can be caugt in between by inadvertent movements. Assemble te product only outside of te operating range of moving parts, at an adequate distance from sources of eat or cold. Prior to perforg work, te product and te macine or system in wic te product is or will be integrated must be depressurized and secured against unautorized activation. Carry out all works on electrical components using voltage insulated tools only. Ensure proper grounding of te product. Undertake drilling at non-critical, nonload bearing parts only. Oter units of te superior macine must not be damaged or impaired in teir function by te installation of te product. No parts of te centralized lubrication system may be subjected to torsion, sear, or bending. Use adequate lifting devices wen working wit eavy components. Avoid mixing up or wrong assembly of disassembled parts. Mark tese parts accordingly. Supply of lubricants witin a centralized lubrication system in intermittent operation following te specifications made in tese Instructions: to establis a progressive system as a multi-line pump for direct supply to individual lubrication points. 11

12 1. Safety instructions 1.9 Foreseeable misuse Any usage of te product differing from te aforementioned conditions and stated purpose is strictly proibited. Particularly proibited are: Use in an explosive atmospere Use of variants wit bottom-mounted SSV metering device in areas wit impact loads and veicles. Use witout te integrated pressure reducing valve Use in continuous operation Painting te pump. Remove or tape pump completely before painting te superior macine Use to feed, forward, or store azardous substances and mixtures in accordance wit annex I part 2-5 of te CLP regulation (EC 1272/2008) Use to feed, forward, or store gases, liquefied gases, dissolved gases, vapours, or fluids wose vapour pressure exceeds normal atmosperic pressure (1013 mbar) by more tan 0.5 bar at te maximum permissible operating temperature. Use to feed, forward, or store glycol- or polyglycol based oils and greases. Tese may damage te reservoir Disclaimer of liability Te manufacturer sall not be eld responsible for damages caused by: inappropriate usage wrong or improper assembly, operation, adjustment, or programg improper or late response to malfunctions unautorized modification of system components te installation of non-original components or spare parts 1.11 Referenced documents In addition to tese instructions, te following documents must be observed by te respective target group: Te instructions of te SSV metering device tat is used. Operational instructions and approval rules Instructions of te suppliers of purcased parts Safety data seet (MSDS) of te lubricant or material used If applicable, project planning documents and oter relevant documents Te operator must supplement tese documents wit te relevant applicable national regulations of te country of use. Wen selling or forwarding te product, make sure to attac tese Instructions to it.. 12

13 1. Safety instructions Residual risks Residual risks Remedy Life cycle transport, assembly, start-up, operation, malfunction, troublesooting, repair, maintenance, sutdown, disposal Dropping of lifted parts or tools Falling of parts troug insufficient fixing to te macine Electrical sock due to defective connection cable People slipping due to floor contaation wit spilled or leaked lubricant No people may remain under suspended loads. Keep unautorized persons away. Secure suspended loads using suitable oisting equipment (e.g. tapes, belts, ropes, etc.). Fix parts only to macine parts wit sufficient load capacity. Observe te weigt. Observe te stated tigtening torques. If no tigtening torques are stated, te tigtening torques are to be applied to te screw size for 8.8 screws. Literature, see screw manufacturer. Ceck connection cable for damages. Be careful wen connecting or disconnecting ydraulic connections Promptly apply suitable binding agents to remove te leaked or spilled lubricant Follow te operational instructions for andling lubricants and contaated parts Tearing or damaging of lines wen installed on moving macine parts Ripping out/ damage to lines at cafing points or due to assembly wit too little bending radius Lubricant spraying out due to faulty component fitting or line connection If possible, do not install on moving parts. If tis cannot be avoided, use flexible ose lines Use protective pipes or spring coils Use suitable ydraulic screw connections and lines for te stated pressures. Ceck tese prior to commissioning for correct connection and damage. 13

14 1. Safety instructions Residual risks Remedy Life cycle transport, assembly, start-up, operation, malfunction, troublesooting, repair, maintenance, sutdown, disposal Bursting reservoir if filled by a ig-performance pump Contact wit stirring paddle during "test operation" witout reservoir after repair. Reservoirs wit follower plate are subjected to spring load Contaation of te environment wit lubricant and wetted parts Strong eating of te motor due to a blockade Damage of te control pcb due to electrostatic discarge wen replacing a defective membrane keypad Loss of electrical protective functions due to fault assembly of te control pcb due to faulty assembly of te control pcb Monitor te filling procedure and stop it wen reacing te max marking of te reservoir Operate pump wit reservoir always Remove reservoir only wen spring is quite released, i.e. te reservoir is empty. If necessary, empty te reservoir first. Provide adequate protective measures - e.g. fastening straps - wen loosening te reservoir. Do not work wit your ead directly above te reservoir Dispose of te parts following te relevant legal/ operational regulations Switc pump off, let parts cool down, eliate cause. Avoid electrostatic carge. Use ESD tools and ESD protective clotes, wear a grounding bracelet After te installation carry out a safety ceck following DIN (conduct and scope of test, see Service instructions ) 14

15 2. Lubricants 2. Lubricants 2.1 General information 2.2 Selection of lubricants 2 NOTICE All products may be used only for teir intended purpose and in accordance wit te Instructions. Intended use is te use of te products to lubricate bearings and friction points wit lubricants witin te pysical limits tat can be found in te relevant product documentation, e.g. operating instructions and product descriptions, e.g. tecnical drawings and catalogues. Particular attention is called to te fact tat azardous materials of any kind, especially tose materials classified as azardous by CLP Regulation EC 1272/2008 annex I, part 2-5 may be filled into SKF centralized lubrication systems and components and delivered and/ or distributed wit suc systems and components only after consulting wit and obtaining written approval from SKF. All products manufactured by SKF are not admitted for use in combination wit gases, liquefied gases, dissolved gases, vapours, or fluids wose vapour pressure exceeds normal atmosperic pressure (1013 mbar) by more tan 0.5 bar at te maximum permissible operating temperature. Oter material wic is neiter lubricant nor azardous substance may be fed only after consultation wit and written approval by SKF. SKF considers lubricants to be an element of system design tat must always be factored wen selecting components and designing a centralized lubrication system. Te lubricating properties of te lubricants are critically important wen making tese selections. NOTICE Observe te instructions from te macine manufacturer regarding te lubricants to be used. Te amount of lubricant required at te lube point is specified by te bearing or macine manufacturer. It must be ensured tat te required lubricant volume is provided to te lubrication point. Oterwise te lubrication point may not receive adequate lubrication, wic can lead to damage and failure of te bearing. Selection of a lubricant suitable for te lubrication task is made by te macine or system manufacturer and/or te operator of te macine or system in cooperation wit te lubricant supplier. Wen selecting a lubricant, te type of bearings or friction points, te expected load during operation, and te anticipated ambient conditions must be taken into account. All economic and environmental aspects must also be considered. 15

16 2. Lubricants 2.3 Approved lubricants NOTICE If required SKF can elp customers to select suitable components for feeding te selected lubricant and to plan and design teir centralized lubrication system. Please contact SKF if you ave furter questions regarding lubricants. It is possible for lubricants to be tested in te company's laboratory for teir suitability for being pumped in centralized lubrication systems (e.g. "bleeding"). You can request an overview of te lubricant tests offered by SKF from te company's service department. NOTICE ly lubricants approved for te product may be used. Unsuitable lubricants can lead to failure of te product and to property damage. NOTICE Different lubricants must not be mixed. Doing so may cause damage and require costly and complicated cleaning of te product or lubrication system. It is recommended tat an indication of te lubricant in use be attaced to te lubricant reservoir in order to prevent accidental mixing of lubricants. Te product described ere can be operated using lubricants tat meet te specifications in te tecnical data. Depending on te product design, tese lubricants may be oils, fluid greases, or greases. Mineral, syntetic, and/or rapidly biodegradable oils and base oils can be used. Consistency agents and additives may be added depending on te operating conditions. Note tat in rare cases tere may be lubricants wose properties are witin permissible limit values but wose oter caracteristics render tem unsuitable for use in centralized lubrication systems. For example, syntetic lubricants may be incompatible wit elastomers. 16

17 2. Lubricants 2.4 Lubricants and te environment 2.5 Lubricant azard 2 NOTICE Lubricants may pollute ground and waters. Lubricants ave to be andled and disposed of properly. Observe te instructions by te macine manufacturer regarding te lubricants to be used. WARNING Risk of slipping and injury Leaking lubricant is azardous due to te risk of slipping and injury. Seal leaks witout delay and remove spilled or leaked lubricant. It is important to note tat lubricants are environmentally azardous, flammable substances tat require special precautionary measures during transport, storage, and processing. Consult te safety data seet from te lubricant manufacturer for information regarding transport, storage, processing, and environmental azards of te lubricant tat will be used. Te safety data seet of a lubricant may be requested from te lubricant manufacturer. 17

18 3. Overview, functional description 3. Overview, functional description 1 reservoir Te lubricant is stored in te reservoir. Depending on te pump variant different reservoir versions are available, e.g. wit follower plate (QLS 301) or wit stirring paddle for grease (QLS 401). 2 Filler fitting Te filler fitting serves to fill te reservoir wit lubricant. 3 Membrane keypad Te membrane keypad serves to display operation and fault messages and to cange parameters (programg) in te case of pumps wit control unit. 4 Pump ousing Te ousing comprises te motor and depending on te pump variant different control printed circuit boards and different connection options (square or bayonet plug) Overview Fig. 1 18

19 3. Overview, functional description 5 Power supply Serves to connect te pump to an external power supply. 6 Signal line Serves to connect te pump to an external control or signal device. 13 Overview Fig Metering devices Serve to meter and distribute lubricant as well as to switc off te pump by means of an indicator pin and proximity switc after reacing te preset number of operating cycles. Different SSV and SSVDV metering devices are available for different kinds of applications. 8 Reservoir venting device Serves to vent te reservoir wen filling it wit lubricant or to vent te reservoir during operation. 13 Emergency lubrication fitting Serves to provide te connected lubrication points wit lubricant, e.g. in case of a defect of te pump

20 3. Overview, functional description 3.1 Described variants of te QLS system Overview Fig. 3 Overview Fig. 4 QLS 301 wit controller QLS 301 witout controller Use of QLS 401 wit controller Use of QLS 401 witout controller QLS wit follower plate - wit and witout controller - 12 / 24 V DC and 120 / 230 V AC - SSV metering device attaced to te rear or bottom - external SSV metering device QLS witout follower plate - wit and witout controller - 12 / 24 V DC and 120 / 230 V AC - SSV metering device attaced to te rear or bottom - external SSV metering device - SSVDV metering device attaced to te rear side (in case of 12 / 24 V DC only) 20

21 3. Overview, functional description 3.2 Mounting positions of te metering devices Rear-mounted metering device Fig. 5 Bottom-mounted metering device Fig. 6 Pump for external metering device Fig wit internal return of lubricant via outlet "2" of te metering device connection of te feed lines wit pressure plastic tubes (Ø 6x1.5 mm) wit external return of lubricant via return line connection "R" of te connection block connection of te feed lines wit pressure plastic tube or steel tube lines (Ø 6x1.5 mm) Te port (12) for te proximity switc of te external SSV metering device is located on te pump ousing. External SSV metering devices are supplied wit a corresponding plug and 2 m connection cable. 21

22 3. Overview, functional description 3.3 Canging te output volume of te SSV metering devices About 0.2 cc of lubricant are supplied per stroke and outlet. Closing unneeded outlets wit closure screws (7.2) increases te output of te next lower open outlet on te same side by te lubricant volume of te upper closed outlets. Maximum number of outlets tat can be crossported internally: SSV 6 = 3 SSV 12 = 6 SSV 18 = 9 Furter crossporting is possible externally only by means of a tee piece. 3.4 Canging te output volume of te SSVDV metering devices Adjust te output volume by screwing te required metering screw (Fig. 9) into te corresponding outlet of metering piston level (B). Additionally te output can be adapted by closing unneeded outlets (see SSV metering device). Metering screws Fig ccm 1.4 ccm 1.0 ccm 0.8 ccm 0.6 ccm 0.08 ccm Adjust output on SSV metering device Fig. 8 Fig. witout indicator pin 12 1x 11 SSVDV metering device Fig. 10 B 3x 7 8 1x x 2x 1 2 1x 22

23 3. Overview, functional description 3.5 Return of unneeded lubricant to te pump Rear-mounted metering device Bottom-mounted metering device External metering device 3 Return is realized internally: for even numbers of outlets - by closing outlet 2 for odd numbers of outlets - by closing outlets 2 and 1 Feed lines are connected to te outlets wit te igest numbers. Te outlets wit te lowest numbers are used for returning te lubricant. Lubricant return is realized externally via return line "R of te connection block. Outlets 1 and 2 must never be closed as oterwise tere may occur a blockade in te metering device. Lubricant return is realized via return line "R of te connection block on te QLS pump. Returned outlets 1, 2, 4 Fig. 11 Connection block Fig. 12 B Lubricant supply C Lubricant included 23

24 3. Overview, functional description 3.6 Membrane keypad In case of pumps wit controller te membrane keypad (3) wit display serves to: display operation states and error codes trigger an additional lubrication display and cange parameters (programg) Membrane keypad wit display Fig. 13 All functions - except from te display of error codes - are available during te pump's pause time only. Pump adjustments are made via te green adjustment key (3.3) and te red switc key (3.2) and are sown on te display (3.1)

25 3. Overview, functional description 3.7 Displays in te display mode S4 control printed circuit board 3.8 Displays in te programg mode S4 control printed circuit board Ready for operation Te pump is in te pause mode. Tere are no fault indications pending. Programg step P1 In tis step te ourly data of te pause time is set.. 3 Pump is on Te pump is in te operating mode. Tere are no fault indications pending. Programg step P2 In tis step te ute value of te pause time is set. Pre-low-level signal Te pump is in te operating mode. Tere is little lubricant available. Te display alternates wit "pump is on". Programg step P3 In tis step te number of metering device cycles per operating cycle is set. Low level indication Lubricant lacks. Te pump terates te current lubrication cycle. It can be restarted only after refilling te reservoir. Programg step P4 In tis step te type of output signal is set. nc = normally closed contact no = normally open contact Fault signal Er An unspecified error is pending. Programg step P5 In tis step it is detered weter a differentiation is made between a fault signal or a low-level signal. Fault signal EP A fault of te membrane keypad is pending. Programg step P6 In tis step it is set ow te pump will start wen being switced on. SP = Start wit pause time SO = Start wit lubrication time 25

26 3. Overview, functional description End of programg Programg as been completed. To adopt te values set te programg as to be confirmed wit te green key 3.3 (see Fig. 13) witin 30 seconds. Start stage SP Wen being switced on te pump starts wit a pause time. Programg step P6 Normally closed contact Output signal is preset as normally closed contact. Programg step P4 Start stage SO Wen being switced on te pump starts wit te lubrication time. Programg step P6 Normally open contact Output signal is preset as normally closed contact. Programg step P4 Fault - low-level signal No differentiation between fault and low-level signal. Programg step P5 Output signal programmed as normally open contact Intermittent low-level signal, functional faults as permanent signal (ON). Programg step P5 Output signal programmed as normally closed contact Intermittent low-level signal, functional faults as permanent signal (OFF). Programg step P5 Remaining pause time Consists of 3 consecutive displays tat cange in a two second interval. Display 1 Display 2 Sows te remaining pause time in ours. Display 3 Sows te remaining pause time in utes. Example: Remaining pause time 1 our and 10 utes. 26

27 3. Overview, functional description AC Sows te number of automatically triggered operating cycles. Counter value (continuous). Te display consists of 3 subsequent displays alternating in a two second interval. Display 1 UC Sows te number of manually triggered additional lubrication cycles. Counter value (continuous). Te display consists of 3 subsequent displays alternating in a two second interval. Display 1 3 Display 2 Sows te values in tousands and undreds. Display 2 Sows te values in tousands and undreds. Display 3 Sows te values in tens and units. Example: 0625 = 625 automatically triggered operating cycles. Display 3 Sows te values in tens and units. Example: 0110 = 110 manually triggered additional lubrication cycles. 27

28 3. Overview, functional description 3.9 Displays in te display mode S5 / S6 control printed circuit board 3.10 Displays in te programg mode S5 / S6 control printed circuit board Ready for operation Te pump is in te pause mode. Tere are no fault indications pending. Pump is on Te pump is in te operating mode. Tere are no fault indications pending. Fault signal Er An unspecified error is pending. Fault signal EP A fault of te membrane keypad is pending. Programg step P1 In tis step te ourly data of te pause time is set.. Programg step P2 In tis step te number of metering device cycles per operating cycle is set. Pause time = Displayed value x 2 Programg step P3 In tis step te number of metering device cycles per operating cycle is set. Pause time = Displayed value x 100 End of programg Programg as been completed. To adopt te values set te programg as to be confirmed wit te green key 3.3 (see Fig. 13) witin 30 seconds. Remaining pause time Consists of 3 consecutive displays tat cange in a two-second interval. Display 1 Display 2 Sows te remaining pause time in ours (displayed value x 100). Display 3 Sows te remaining pause time in ours (displayed value x 1). 28 Example: Remaining pause time 110 ours.

29 4. Tecnical data 4. Tecnical data 4.1 General tecnical data Pump variant 12 V DC 24 V DC 120 V AC 60 Hz 230 V AC 50 Hz Admissible operating temperature -25 C to 70 C Operating pressure 205 bar max. Installation position QLS 301 any 1) QLS 401 vertical (max. deviation± 5 ) Lubrication points max. 18 Sound pressure level < 70 db (A) Reservoir size QLS 301 QLS litre 1 litre or 2 litres Filling via ydraulic lubrication fitting R 1/4 Weigt of empty pump wit SSV 12 metering device approx. 6 kg Lubricants 3) Lubricating greases NLGI II and NLGI III 2) / fluid greases NLGI 00, 000 Output 2) approx ccm (per stroke) approx. 1.0 ccm (per ute) Maximum pump run time 30 utes 1) also rotating installation, like e.g. in wind turbine generators. Maximum speed and maximum distance to te ub on request. 2) NLGI III lubricants may be supplied under certain operating conditions only. Terefore te lubricant's supply caracteristics as to be clariefied wit SKF in advance. 3) Observe te references given in capter 4.6 and 4.7. Temperature [ C]: -25 C -20 C +25 C 012 V DC Speed [rpm] V DC Speed [rpm] V AC Speed [rpm] V AC Speed [rpm] 2.5-5, Te stated speed depends on te back pressure and te temperature. Basically te following applies: te iger te back pressure and te lower te temperature, te lower is te speed. 4 29

30 4. Tecnical data 4.2 Electrics Pump variant 12 V DC 24 V DC 120 V AC 60 Hz IP protection class of bayonet plug 6K9K 6K9K Power supply wit square plug (left side) yes yes yes yes 230 V AC 50 Hz Tolerance of input voltage -20 / + 30 % -20 / + 30 % ±10 % ±10 % Current input (maximum) 2 A 1 A 1 A 0.5 A Types of protection Inputs PELV protected against reverse polarity, sort circuit proof, non-isolated Power supply wit bayonet plug (left side) yes yes no no Power supply and fault signal wit bayonet plug (left side) yes yes no no Fault signals wit square plug (rigt side) yes yes yes yes Protective and disconnecting device required for isolation yes yes yes yes Switcing voltage 48 V AC / DC 48 V AC / DC 48 V AC / DC 48 V AC / DC IP protection class of bayonet plug 65 / 67 # 65 / 67 # 65 65/67# AC fault relay for low level signal and fault signals 230 V AC 230 V AC 230 V AC 230 V AC maximum switced current 5 A 5 A 5 A 5 A DC fault relay for low level signal and fault signals 24 V DC 24 V DC 24 V DC 24 V DC maximum switced current 5 A 5 A 5 A 5 A Residual ripple (DIN 41755) ±5 % ±5 % ±5 % ±5 % # IP 67 only for square plugs wit prefabricated cable 30

31 4. Tecnical data 4.3 Factory settings of pumps wit S4 control printed circuit board Programg step/ value Factory setting Setting range P1 Pause time in ours 6 ours 0-59 ours P2 Pause time in utes 0 utes 0-59 utes P3 Metering device cycles per operating cycle 1 cycle V DC pumps 1-5 cycles V AC pumps 1-3 cycles # P4 Signal output fault relay no NO contact / NC contact P5 Differentiation of low-level signal and fault signal -- P6 Start stage Maximum runtime 30 utes not modifiable SP -- (no differentiation) -U (output signal as nc contact) -Π (output signal as no contact) [SP] Pump starts wit pause time [SO] Pump starts wit lubrication time 4 Maxmum adjustable pause time = 59 ours 59 utes Minimum adjustable pause time V DC pump = 4 utes Minimum adjustable pause time V AC pump = 20 utes # For te AC versions adere to te following values in order to avoid pump failure due to exceeding te max. runtime: - for SSV 6 and SSV 8 metering devices a maximum of 3 cycles - for SSV 12 and SSV 18 metering devices a maximum of 1 cycle 31

32 4. Tecnical data 4.4 Factory settings of pumps wit S5/ S6 control printed circuit boards Programg step/ value Factory setting Setting range P1/ P2 Pause time in ours 1600 (P1=16; P=00) P3 Metering device cycles per lubrication cycle* 60 cycles (P3 = 60) 1-99 cycles Signal output S5 normally closed contact S6 normally open contact not modifiable Differentiation of low-level signal and fault signal no differentiation not modifiable Start stage Te pump starts wit a pause time. not modifiable Maximum runtime 15 utes not modifiable Maximum adjustable pause time between te lubrication cycles = 9998 ours; imum adjustable pause time V DC and V AC pumps = 2 ours Increment of pause time setting: P1 = 100 ours (example: 100, 200, 300 ); P2 = 2 ours (example: 2, 4, 6, 8 ) * A lubrication cycle is completed as soon as te preset number of metering device cycles (P3) as been completed successfully. Between te individual metering device cycles tere is a fixed interval pause of 4 utes. During te interval pause te display sows te metering device cycles of te current lubrication cycle still to be carried out. During te interval pause no additional lubrication can be triggered, nor can parameters be canged or displayed. If during te interval pause te power supply to te pump is interrupted, te interval pause will start from te beginning. In case of frequent interruptions during te interval pause tis can result in te fact tat no metering device cycle will be started anymore and tus te lubrication cycle cannot be completed. Reset te S5/S6 printed circuit board to te factory settings. Switc off te power supply. Press te green and red keys simultaneously. Switc on power supply again. In te display tere appears te fault low-level signal (see page 26) Release te green and red keys, Switc te power supply off and on again. 32

33 4. Tecnical data 4.5 Functioning principle of te intermittent low-level indication Te intermittent low-level indication operates free of contact. Its main components are te following: firmly positioned magnetic switc (I) inside of te reservoir bottom flexible guide plate (II) connected to te stirring paddle wit a magnet (III) and a control cam (IV) If te reservoir is filled wit a lubrication grease suitable for te intermittent low-level indication and te pump is operating, ten te guide plate (II) is deflected by te resistance of te lubrication grease. As a consequence te magnet (III) connected to te guide plate (II) is moved on its inner circuit and does not trigger a pulse of te magnetic switc (I) wit its magnetic field. A control cam (IV) positively guides te round magnet togeter wit te pivoted guide plate towards te outside during eac revolution. As soon as te guide plate leaves te control cam, te lubricant's resistance puses te guide plate togeter wit te magnet to te inside again. As soon as te lubricant inside te reservoir as fallen to tat level tat te lubricant's resistance is no more sufficient to furter deflect te guide plate (II), te magnet (III) remains on te outer circuit and triggers a pulse eac time it slides across te magnetic switc (I). If during an operating cycle te magnet (III) slides across te magnetic switc (I) six times, a low-level signal is sent by te control printed circuit board of te pump. For programg of te external control of te pump, see corresponding capter in tese instructions. 4 Perspective representation Magnet on inner circuit Perspective representation Magnet on outer circuit I II IV III I I 33

34 4. Tecnical data Operating limits of te intermittent low-level indication Te following lubricant consistencies ave to be complied wit in order to ensure te correct functioning of te intermittent low-level indication. Above te stated range of temperature a correct functioning of te intermittent low-level indication cannot be ensured. Te inferior temperature ranges require te suitability of te lubricant for te respective temperature range. Oterwise te too ig consistency of te lubricant may result in malfunctions, e.g. interruption of te lubricant supply, or in damages to te pump (e. g. bending of te stirring paddle). Te intermittent low-level indication is not appropriate for lubricants of NLGI class C -10 C 0 C +10 C +20 C +30 C +40 C +50 C +60 C +70 C NLGI 0.5 NLGI 1.0 NLGI 1.5 NLGI

35 4. Tecnical data Processing of te low-level signals in case of external control and monitoring of te pump Te statements apply for pumps witout control pcb wit external control and monitoring by te operator. To avoid early low-level indication (e.g. caused by air inclusions or wave formation in te lubricant) in case of external controller or monitoring te following conditions ave to be fulfilled by programg te external controller accordingly. After eac operating cycle te pulses of te intermittent low-level indications ave to be deleted. 4 Pulses must never be added up over several operating cycles. Tis will result in an early low-level indication. Operating cycle 32 seconds: 'Eac operating cycle requires at least 6 signals by te magnetic switc. Operating cycle 24 seconds 32 seconds: 'Eac operating cycle requires at least 4 signals by te magnetic switc. Operating cycle 24 seconds: Te number of required magnetic switc signals as to be adapted to te operating conditions to be expected. To do so, contact our Customer Service. Visualization of a low-level indication: Te low-level signal is visualized via an external control ligt as sown in te connection diagram. Remaining run time of pump in case of a low-level indication Pumps wit external controller Te owner as to ensure tat te pump is stopped by te external control unit latest 4 utes after te low-level signal. 35

36 4. Tecnical data 4.6 Tigtening torques Adere to te following tigtening torques wen installing or repairing te pump. Pump wit base plate, macine, or veicle Metering device wit QLS pump Pump element wit pump ousing Outlet fitting on metering device screw-in type plug-in type Indicator pin fitting Closure screw (outlet) Closure screw (piston) Coupling nut on outlet fitting Plastic tube Steel tube Cover of pump ousing Reservoir wit pump ousing 18 Nm ± 1 Nm 9 Nm ± 1 Nm 25 Nm ± 2 Nm 17 Nm ± 1 Nm 12 Nm ± 1 Nm 18 Nm ± 1 Nm 15 Nm ± 1 Nm 18 Nm ± 1 Nm 10 Nm ± 1 Nm 11 Nm ± 1 Nm 1.6 Nm Nm 7 Nm + 1 Nm 36

37 4. Tecnical data 4.8 Useable reservoir volume Te useable reservoir volume mainly depends on te NGLI consistency class and te operating temperature of te lubricant to be used. In case of ig consistency and low operating temperature normally more lubricant sticks to te inner surfaces of te reservoir/ pump and is tus no more available for being dispensed. Useable reservoir volume 1-litre reservoir witout low level indication (XN) Useable reservoir volume 2-litre reservoir witout low level signal (XN) 4 Lubricants wit relatively ig consistency 4) 0.5 litres approx. 1.6 litres Lubricants wit relatively low consistency 5) approx. 1.0 litre approx. 2.0 litres Useable reservoir volume 1-litre reservoir wit low level indication (XL) Useable reservoir volume 2-litre reservoir wit low level indication (XL) Lubricants wit relatively ig consistency 4) approx. 0.5 to 0.8 litres approx. 1.6 to 1.9 litres Lubricants wit relatively low consistency 5) approx. 0.6 to 0.9 litres approx. 1.7 to 2.0 litres 4) Lubricant consistencies of NLGI 2 lubricants at + 20 C up to te maximum admissible lubricant consistency. 5 ) Lubricant consistencies of NLGI-000 lubricants at + 70 C up to lubricant consistencies of NLGI-1.5 lubricants at + 20 C. 4.9 Lubricant requirement for prig of an empty pump To prime an empty pump up to te MAX marking of te reservoir, te following lubricant quantities are required. Reservoir size 1 litre Quantity 1.75 litres ± 0.15 Wen using lubricants of a relatively low consistency in pumps subjected to srong vibrations or tilting motions (e.g. construction and agricultural macinery), make sure to maintain a level tat is about 25 mm below te MAX marking of te reservoir. Tis prevents lubricant from entering te reservoir 2 litres 3.0 litres ± 0.10 vent. In case of very strong vibrations tis value must be increased, for low vibrations it can be reduced. Canging te filling level by 10 mm corresponds to a volume cange of about 0.2 litres. 37

38 4. Tecnical data 4.10 Notes related to te type identiication plate Te type identification plate states important caracteristics suc as type designation, order number, UL and/or e1 pproval, etc. To ensure tat te loss of data due to an illegible type identification plate is avoided, te caracteristics sould be entered in te Instructions. P. No. S. No. Model 4.11 Notes related to te CE marking CE marking is effected following te requirements of te applied directives: 2014/30/EU Electromagnetic compatibility 2011/65/EU (RoHS II) Directive on te restriction of te use of certain azardous substances in electrical and electronic equipment Reference on Low Voltage Directive 2014/35/EU Te protective regulations of Low Voltage Directive 2014/35/EU are fulfilled according to annex I (1.5.1) of Macinery Directive 2006/42/EC. Reference on Pressure Equipment Directive 2014/68/EU Because of its performance data te product does not acieve te limit values defined in Article 4 (1) (a) (i) and is terefore excluded from te scope of application of Pressure Equipment Directive 2014/68/EU following Article 4 (3). Type identification plate Fig. 14 Type identification plate wit UL and e1 approval Fig. 15 SKF Lubrication Systems Germany GmbH Code: PXXXXXXXXXXX Model: P-XXXX-XXXXX-XXX-XXXXXXXXXXXXXXXX P. No.: P650-XXXXX-X S. No.: 20XXXXXXXXXXXXXX pmax: U: P: xxx bar / xxxx psi 24 VDC / - Hz Pase - 24 W Made in Czec Republic S. No.: 20XXXXXXXXXXXXXX KW/JJ SKF Lubrication Systems Germany GmbH Code: PXXXXXXXXXXX Model: P-XXXX-XXXXX-XXX-XXXXXXXXXXXXXXXX P. No.: P650-XXXXX-X e1 S. No.: 20XXXXXXXXXXXXXX C UL US pmax: U: P: xxx bar / xxxx psi 24 VDC / - Hz Pase - 24 W Made in Czec Republic S. No.: 20XXXXXXXXXXXXXX LISTED Factory Automation Eqiupment 77 MM KW/JJ 38

39 4. Tecnical data 4.11 Type identiication code QLS 301 Identification code P Basic type of pump P301 Metering devices 0 = external metering device SSV 6-KNQLS, SSV 8-KNQLS 1 = external metering device SSV 12-KNQLS, SSV 18-KNQLS 3 = SSV 6 (rear-mounted) 4 = SSV 8 (rear-mounted) 6 = SSV 12 (rear- or bottom-mounted) 9 = SSV 18 (rear- or bottom-mounted) Assignment of metering device outlets 0 = no metering device 1 = vertical metering device outlets (V) 2 = orizontal metering device outlets (H) Supply voltage 2 = 12 V DC (available wit or witout control pcb) 4 = 24 V DC (available wit or witout control pcb) 6 = 120 V AC (available wit control pcb only) 8 = 230 V AC (available wit control pcb only) Reservoir version 1 = 1XL,3, (1-l reservoir wit low-level indication) * Connection types 1, 5, 6 can be combined wit square plug version (1) only. ** Connection types 7, 8 can be combined wit bayonet plug version (5) only. Control pcb's witout = 0 Control pcb S4 for 12/ 24 V DC = 4 NC and NO contacts programmable 1-5 cycles Control pcb S4 for 120/ 230 V AC = 4 NC and NO contacts programmable 1-3 cycles (SSV 6/ SSV 8) 1 cycle (SSV 12/ SSV 18) Types of electrical connection *wit connection socket, witout cable = 1 *wit connection socket and 10 m cable = 5 *wit connection socket and 10 m ADR cable = 6 **wit connection socket (bayonet) and 10 m cable = 7 **wit connection socket (bayonet) and 10 m ADR cable = 8 Connection socket design *Square plug design A (industry) = 1 **Bayonet plug 4-pole design (veicles) = 5 Number of possible connections 1 connection left side, power supply (V DC/ V AC) 1A = 0 Square plug, industrial applications 1 connection left side, power supply (V DC) 1A = 2 Low-level or fault indication, bayonet plug, veicles only 2 connections, 1 x left side for power supply (V DC/ V AC) 2A = 1 1 x rigt side for external low-level or fault indication square plug, industrial applications 4 39

40 4. Tecnical data 4.13 Type identiication code QLS 401 Identification code P Basic type of pump P401 Metering devices 0 = external metering device SSV 6-KNQLS, SSV 8-KNQLS 1 = external metering device SSV 12-KNQLS, SSV 18-KNQLS 3 = SSV 6 (rear-mounted) 4 = SSV 8 (rear-mounted) 6 = SSV 12 (rear- or bottom-mounted) 9 = SSV 18 (rear- or bottom-mounted) Assignment of metering device outlets 0 = no metering device 1 = vertical metering device outlets (V) 2 = orizontal metering device outlets (H) Supply voltage 2 = 12 V DC (available wit or witout control pcb) 4 = 24 V DC (available wit or witout control pcb) 6 = 120 V AC (available wit control pcb only) 8 = 230 V AC (available wit control pcb only) Reservoir version 0 = 1XN (1-l reservoir witout low-level indication) 1 = 1XL,3, (1-l reservoir wit low-level indication) 2 = 2XN (2-l reservoir witout low-level indication) 3 = 2XL, 3, (2-l reservoir wit low-level indication) * Connection types 1, 5, 6 can be combined wit square plug version (1) only. ** Connection types 7, 8 can be combined wit bayonet plug version (5) only. # Control pcb's can be combined wit XN reservoir versions only. Control pcb's witout = 0 Control pcb S4 for 12/ 24 V DC = 4 NC and NO contacts programmable 1-5 cycles Control pcb S4 for 120/ 230 V AC = 4 NC and NO contacts programmable 1-3 cycles (SSV 6/ SSV 8) 1 cycle (SSV 12/ SSV 18) Control pcb S5 for 12/ 24 V DC NC contact signal = 5 # Control pcb S5 for 120/ 230 V AC NC contact signal = 5 # 1-3 cycles (SSV 6/ SSV 8) 1 cycle (SSV 12/ SSV 18) Control pcb S6 for 12/ 24 V DC NO contact signal = 6 # Control pcb S6 for 120/ 230 V AC NO contact signal = 6 # 1-3 cycles (SSV 6/ SSV 8) 1 cycle (SSV 12/ SSV 18) Types of electrical connection *wit connection socket, witout cable = 1 *wit connection socket and 10 m cable = 5 *wit connection socket and 10 m ADR cable = 6 **wit connection socket (bayonet) and 10 m cable = 7 **wit connection socket (bayonet) and 10 m ADR cable = 8 Connection socket design *Square plug design A (industry) = 1 **Bayonet plug 4-pole design (veicles) = 5 Number of possible connections 1 connection left side, power supply (V DC/ V AC) 1A = 0 Square plug, industrial applications 1 connection left side, power supply (V DC) 1A = 2 Low-level or fault indication, bayonet plug, veicles only 2 connections, 1 x left side for power supply (V DC/ V AC) 2A = 1 1 x rigt side for external low-level or fault indication square plug, industrial applications 40

41 4. Tecnical data 4.14 Type identiication code QLS 401 SSVDV Identification code P401 SSVDV16 AAAABBBB 24DC 1XN 2A 1 5 S4 Basic type of pump P401 Metering devices SSVDV 6 (rear-mounted, vertical outlets (V) SSVDV 12 (rear-mounted, vertical outlets (V) SSVDV 16 (rear-mounted, vertical outlets (V) Metering screws per pair of outlets A = 0.08 cc / B = 0.14 cc / C = 0.20 cc / D = 0.30 cc E = 0.40 cc / F = 0.60 cc / G = 0.80 cc / H = 1.00 cc I = 1.40 cc / J = 1.80 cc Marks te mounted metering screws per pair of outlets, starting wit te igest pair of outlets. Te number of metering screws in te identification code corresponds to alf of te metering device's outlets. Supply voltage 12 V DC (available wit or witout control pcb) 24 V DC (available wit or witout control pcb) Reservoir version 1XN (1-l reservoir witout low-level indication) 1XL (1-l reservoir wit low-level indication) 2 XN (2-l reservoir witout low-level indication) 2XL (2-l reservoir wit low-level indication) * Connection types 1, 5, 6 can be combined wit square plug version (1) only. ** Connection types 7, 8 can be combined wit bayonet plug version (5) only. Control pcb's witout Control pcb S4 for 12/ 24 V DC Programmable NC and NO contacts, 1-5 cycles Types of electrical connection *wit connection socket, witout cable = 1 *wit connection socket and 10 m cable = 5 *wit connection socket and 10 m ADR cable = 6 **wit connection socket (bayonet) and 10 m cable = 7 **wit connection socket (bayonet) and 10 m ADR cable = 8 Connection socket design *Square plug design A (industry) = 1 **Bayonet plug 4-pole design (veicles) = 5 Number of possible connections 1 connection left side, power supply 1A Square plug, industrial applications 1 connection left side, power supply 1A Low-level or fault indication, bayonet plug 2 connections, 1 x left side for power supply 2A 1 x rigt side for external low-level or fault indication square plug Tis pump type allows for V DC variants only. 4 41

42 5. Delivery, returns, and storage 5. Delivery, returns, and storage 5.1 Delivery Te products are packaged following te standard commercial practice according to te regulations of te recipient's country. During transport safe andling must be ensured. After receipt of te sipment, te product(s) must be inspected for damage and for completeness according to te sipping documents. Keep te packaging material until any discrepancies are resolved. 5.2 Return Clean all parts and pack tem properly before returning tem. Protect te product against mecanical influences suc as impacts. Tere are no restrictions for land, sea or air transport. Mark returns on te packaging as follows. 5.3 Storage Marking of returns Fig. 16 SKF products are subject to te following storage conditions: dry and dust-free surroundings, storage in well ventilated dry area Storage time: 24 monts max. Permissible umidity: < 65% (r) Permissible storage temperature: C/ max C avoid direct sun or UV exposure sield product from nearby sources of eat and coldness. 5.4 General notes related to storage Te product(s) can be wrapped in plastic film to provide low-dust storage Protection against ground moisture by storing on a self or wooden pallet. 42

43 6. Assembly 6. Assembly 6.1 General information ly qualified tecnical personnel may install, operate, maintain, and repair te products described in tese Instructions. Qualified tecnical personnel are persons wo ave been trained, assigned, and instructed by te operator of te final product, into wic te described product sall be integrated. Suc persons are familiar wit te relevant standards, rules, accident prevention regulations, and operating conditions as a result of teir training, experience, and instruction. Tey are qualified to carry out te required activities and in doing so recognize and avoid any potential azards. Before assembling te product, te packaging material as well as possible transport locking devices must be removed. Keep te packaging material until any discrepancies are resolved. 6.2 Attacment Protect te product against umidity and vibration and install it in an easily accessible position to ensure all oter installations can be carried out witout any problem. For indications on te maximum admissible ambient temperature see te tecnical data. During assembly and particularly during any drilling work always pay attention to te following: Oter units must not be damaged by te assembly. Te product must not be installed witin te range of moving parts. Te product must be installed at an adequate distance from sources of eat and coldness. Adere to safety distances and legal prescriptions on assembly and prevention of accidents. CAUTION Electric sock Make sure to disconnect te product from te power supply before carrying out works on any part of it. Connection of te pump must be provided by a safe galvanic isolation (PELV) always. 6 NOTE Tecnical data (see capter 4). 43

44 6. Assembly 6.3 Minimum assembly dimensions Ensure sufficient space for maintenance work or for a possible disassembly of te product by leaving a free space of at least 50 mm into eac direction in addition to te stated dimensions. Minimum assembly dimensions Fig. 17 A = eigt 230 mm (1-l reservoir) 7) A = eigt 313 mm (2-l reservoir) 7) B = widt 237 mm C = dept 215 mm 7) in case of bottom-mounted metering device + 40 mm 8) in case of rear-mounted SSVDV metering device + 20 mm A A B C # 44

45 6. Assembly 6.4 Connecting dimensions Te pump is fastened on te two mounting bores. Fastening is done by means of te fastening material included in te scope of delivery. 2 x M8 screw 2 x M8 nut (self-locking) 2 x waser Tigtening torque = 18 Nm Connecting dimensions Fig. 18 Connection dimensions E = ole distance 146 mm F = eigt 110 mm 6 E F 45

46 6. Assembly 6.5 Electrical connection Electrical connections must be done in suc way tat no forces are transferred to te product (tension-free connection). For electrical connection proceed as follows: Square plug Use adequate cable to configure square plug witout cable. For connection of te cable, see wiring diagram on square plug or corresponding wiring diagram in tese Instructions (see capter 12). Remove protective caps from te electrical connections of te pump. Place plugs wit sealing onto connections and fasten tem by means of a screw. Bayonet plug Remove protective caps from te electrical connections of te pump. Place plugs onto connections and fasten tem by turning tem. In case of te bayonet plugs prefabricated by te operator, pin assignment is done in accordance wit te wiring diagram in tese Instructions (see capter 12). NOTE Observe te electrical caracteristics (see capter 4). 46

47 6. Assembly 6.6 Prig of pumps witout follower plate To prime te pump proceed as follows: Position bin below te pump to collect leaking lubricant. Screw out te yellow transport locks (7.1) from te metering device outlets. Close unneeded outlets of te metering device wit closure screws. Place filling connection of grease gun or transfer pump onto filler fitting (2). Fill reservoir wit lubricant until te MAX marking (Fig. 20). To do so, observe te notes contained in capter 4.8. Press key (3.1) to let te pump run until lubricant leaks from te open outlets of te metering device. Switc te pump off. Mount te primed lubricant lines to te open outlets of te metering device and ten connect tem to te lubrication points. Remove lubricant collecting bin and dispose of leaked lubricant in an ecologically sound manner. Rear view Fig Te pump is now ready for operation wit te factory settings or can be adapted accordingly by canging te relevant parameters (programg) Front view Fig

48 6. Assembly 6.7 Prig of te QLS 301 wit follower plate NOTICE Risk of damage to te superior macine due to wrong prig. Avoid air pockets in te lubricant and under te follower plate. Tis may affect te pump's suction beaviour and result in a poor or lacking output performance. NOTICE To prime an empty QLS 301 proceed as follows: Unscrew Allen key M5 (1.4) out of te reservoir axis and keep it for furter usage togeter wit te below sealing ring. Remove reservoir (1) upwards. If necessary, sligtly loosen reservoir on te side close to te reservoir centering device (1.5) by means of a blunt tool. Remove te spring (1.3). Position grease gun on filler fitting (2). Reservoir centering device Fig Damage to te pump Make sure tat no dirt enters te reservoir during te filling procedure. Do not overfill te reservoir. Consider lubricant expansion by increased temperature (important, e.g. for storage or transport of te pump) or by pressure relief after te filling procedure (reservoir vent clogged by lubricant). 1 Remove screw Fig Reservoir and spring removed Fig

49 6. Assembly Press follower plate (1.1) downward onto te pump ousing. Fill pump until follower plate (1.1) starts lifting and some lubricant leaks out from te side (see Fig. 25). Sligtly grease sealing lip (1.2) of follower plate wit te leaking lubricant. Position spring (1.3) on reservoir axis again. Manually press reservoir over te O-ring completely downwards. Ensure tat te reservoir centering device (see Fig. 22) is firmly seated in te corresponding recess of te pump ousing. Use Allen key M5 (1.4) to screw reservoir togeter wit waser onto te reservoir axis again. Tigtening torque = 1.5 Nm Fill reservoir until sortly below te MAX marking. Remove possible contaations from te reservoir outside. 1.2 Fill space under te reservoir Fig Lateral lubricant leakage Fig. 25 Reservoir mounted again Fig Filling te reservoir Fig

50 6. Assembly 6.8 Programg of control pcb S4 To program QLS pumps wit control pcb S4 proceed according to te following programg sceme. Simultaneously press key 3.2 and key 3.3 for about 4 seconds to access te first programg step P1. After releasing te keys te adjusted value will be displayed. Cange te value of te programg step by pressing key 3.3. Confirm adjusted value witin 30 seconds by pressing key 3.2. Oterwise te value will be lost. Programg is continued wit programg step P2. After confirg te last step P6 te programg is completed. Programg steps P1/ P2 Setting of te pause time in ours P1/ P2 Setting of te pause time in utes P3 Setting of te metering device cycles P4 Setting of te output signal on te monitoring relay P5 Setting of te differentiation between fault and low-level signal. P6 Setting of te start stage A = Programg step B = Possible value C = Cange value by pressing te key D = Possible new value E = Confirm adjusted value witin 30 seconds by pressing key 3.2 and continue wit te next programg step. Confirm and finis te programg by pressing key 3.3 after te last programg step. 3.3 & > 4 S 3.2 A B C Notes related to te programg Settings can be done in one direction only (+) Fast forward by olding down key 3.3. Programg sceme of control printed circuit board S4 Fig. 28 D E

51 6. Assembly 6.9 Programg of control printed circuit boards S5 and S6 To program QLS pumps wit control pcb S5/ S6 proceed according to te following programg sceme. Simultaneously press key 3.2 and key 3.3 to access te first programg step P1. After releasing te keys te adjusted value will be displayed. Cange te value of te programg step by pressing key 3.3. Confirm te canged value. Programg is continued wit programg step P2. Cange te value of te programg step by pressing key 3.3. Confirm te canged value. Programg is continued wit programg step P3. Cange te value of te programg step by pressing key 3.3. Confirm te canged value. After confirg tis step te programg is completed. Programg steps P1 Setting of te pause time in steps of 100 ours (display x 100) P2 Setting of te pause time in steps of 2 ours (display x 2) P3 Setting of te metering device cycles per operating cycle A = Programg step B = Possible value C = Cange value by pressing te key D = Possible new value E = Confirm adjusted value witin 30 seconds by pressing key 3.2 and continue wit te next programg step. Confirm and 3.3 & Programg sceme of control printed circuit board S5/S6 Fig A B C 3.2 finis te programg by pressing key 3.3 after te last programg step. Notes related to te programg Settings can be done in one direction only (+) Fast forward by olding down key 3.3. D E x 100 x

52 7. Start-up 7. Start-up 7.1 General information Start-up of te fully and correctly mounted QLS pump is effected via te macine contact or te driving switc. If "EP", "Er" is displayed after switcing te pump on, a fault is pending. NOTE S4 control printed circuit board: If te power supply is interrupted witin 1 ute from switcing te pump on, after switcing te pump on again te pause time starts from te beginning. If te power supply is interrupted after 1 ute from switcing te pump on, after switcing te pump on again te pause time will continue from were it ad been interrupted. S5/S6 control printed circuit board: In case of an interruption of te power supply only te full our values will be stored as pause time. Te utes values will be lost (max. loss = 59 utes per interruption of te power supply). In case of frequent interruptions of te power supply, te actual pause time may differ significantly from te preset pause time. 7.2 Triggering an additional lubrication cycle To trigger an additional lubrication cycle proceed as follows: Press te reset key (3.3) for > 2 seconds. Te pump starts a lubrication cycle. At te same time te pause time already lapsed is reset. In te display tere appears te symbol "Pump on". NOTE S4 control printed circuit board: Te duration of te additional lubrication corresponds to te preset number of metering device cycles per lubrication cycle. S5/S6 control printed circuit board: Te duration of te additional lubrication corresponds to one metering device cycle. 3.3 Trigger an additional lubrication Fig

53 8. Operation, sutdown and disposal 8. Operation, sutdown and disposal 8.1 General information After correct electrical connection and filling wit lubricant te pump is ready for operation. Start-up respectively sutdown is effected by switcing te superior macine or veicle on or off. 8.2 Filling te reservoir during operation NOTICE Damage to te pump Make sure tat no dirt enters te reservoir during te filling procedure. Do not overfill te reservoir. Consider lubricant expansion by increased temperature. Filling via iller itting Connect te filling adapter to te filler fitting (5) and fill reservoir wit lubricant until sortly below MAX marking. To do so, observe te notes contained in capter Temporary sutdown Temporarily sut te system down by disconnecting it from te power supply. 8.4 Sutdown and disposal In case of final sutdown follow te applicable rules and regulations on disposal. Te product can also be returned to te manufacturer for proper disposal, in wic case te customer is responsible for reimbursing te costs incurred. Te parts are recyclable. Disposal Fig