Quicklub. Pump Model 203 with Power Supply for VAC and Printed Circuit Board M08-M23. Owner Manual Technical Description

Transcription

1 Quicklub Pump Model 203 with Power Supply for VAC and Printed Circuit Board M08-M b04

2 Fields of Application of Quicklub Progressive Centralized Lubrication Pumps Industry - Machines Pump Type Pump: Reservoir: Low Level Control: Quicklub 203 with integrated power supply unit 2 L -2XL 2), 2XLBO 1), 2YLBO 3) 4 L -4XLBO 1), 4YLBO 3) 8 L - 8XLBO 1), 8YLBO 3) 1) Filling from the top or bottom 2) Filling only from the bottom 3) Filling only from the top for all reservoir sizes available (exclusion: flat type reservoir) Control: with control unit M08 to M23 4) 4) See the respective model designation on the pump nameplate e.g. P203-2XL-1K6-AC-3A6.15- M08 Further information can be found in the following manuals: Progressive Metering Devices for Grease and Oil, model SSV, SSV M and SSV D Installation Instructions Parts Catalogue Parts Catalogue Pump 103, 223 and 203 All rights reserved. Any duplication of this User Manual, in its entirety or in part, by whatever means is prohibited without the prior consent in writing of Lincoln GmbH & CO. KG. Subject to modifications without prior notification by LINCOLN GmbH & Co. KG Postfach 1263 D Walldorf Phone: +49 (6227) 33-0 Fax: +49 (6227) Page 2 of 44

3 Table of Contents Page Page Fields of Application... 2 Introduction... 4 Explanation of Symbols Used... 4 User s Responsibility... 4 Environmental Protection... 4 Service... 4 Safety Instructions... 5 Appropriate Use... 5 Misuse... 5 General Safety Instructions... 5 Regulations for Prevention of Accidents... 5 Operation, Repair and Maintenance... 5 Disposal... 6 Exclusion of Liability... 6 Installation... 6 Pump Types... 7 Identification Code... 8 Description... 9 The Quicklub 203 centralized lubrication pump... 9 Low Level Control... 9 Mode of operation Pump Elements with fixed Lubrication output Pump element B7 with bypass check valve Check valve Arrangement of the pump elements Pump Elements with adjustable Lubrication output Setting of adjustable pump elements Retrofit adjustment of max. lubricant output Retrofit adjustment of min. lubricant output Pressure relief valve without grease return with grease return Return Line Connection Low Level Control (Option) - for Oil: Float magnetic switch Contact protection measures for grease Reservoir filled Reservoir empty Printed Circuit Boards M08-M Fields of Application Installation position of the printed circuit board Advantages Start up Applications Control Unit Mode of Operation Pause time Operating time Monitoring time Time storage Time Setting Setting Pause time Factory Setting Functional Check and Fault Indication Functional check when switching on Operational test / To trigger an additional lubrication cycle Signal Output Acknowledging receipt of a malfunction Function of the pushbutton for additional lubrication cycles LED function (M08-M23) LED function (M16-M23) Fault Indication M08-M M16-M To Remedy to a Fault Maintenance, Repair and Tests Maintenance Pump Filling...27 Repair Pump Replace pump element Printed Circuit Boards Tests Operational Test / To trigger an Additional Lubrication Cycle To check the pressure relief valve Functional Check of the p.c.b Troubleshooting Technical Data Electrical Data Connection Diagram Combination of the jumper positions - Survey Terminals of the p.c.b Attaching Bores Dimensions Declaration of the Manufacturer Lubricants Keep this user information always at hand at the place of work of the pump! Page 3 of 44

4 Introduction Explanation of Symbols Used The following description standards are used in this manual: Safety Instructions Structure of safety instructions: Pictogram Signal word Danger text - Danger note - How to avoid danger The following pictograms are used in this manual and are combined with the corresponding signal words: 1013A a00 - ATTENTION - CAUTION - WARNING - ATTENTION - CAUTION - WARNING - - IMPORTANT The signal words give the seriousness of danger if the following text is not observed: Furthermore, you will find the following text symbols in this manual: Listing of applicable statements - Subpoint of applicable statements 1. Determination of the number or sequence of contents Procedural instruction User's Responsibility To ensure the safe operation of the unit, the user is responsible for the following: 1. The pump / system shall be operated only for the intended use (see next chapter "Safety Instructions") and its design shall neither be modified nor transformed. 2. The pump / system shall be operated only if it is in a proper functioning condition and if it is operated in accordance with the maintenance requirements. 3. The operating personnel must be familiar with this Owner Manual and the safety instructions mentioned within and observe these carefully. The correct installation and connection of tubes and hoses, if not specified by Lincoln GmbH & Co. KG, is the user's responsibility. Lincoln GmbH & Co. KG will gladly assist you with any questions pertaining to the installation. ATTENTION CAUTION WARNING IMPORTANT Example: 1013A94 refers to faults or damages on machines. refers to bad damages and possible injuries. refers to possible dangerous injuries. refers to improvements in handling of systems. refers to considerable disadvantages in handling of systems. ATTENTION! When making use of other than the tested spare parts, serious damage may affect your device. Therefore, for the operation of your device always use original spare parts made by Lincoln GmbH & Co. KG. Environmental Protection Waste (e.g. used oil, detergents, lubricants) must be disposed of in accordance with relevant environmental regulations. Service The personnel responsible for the handling of the pump / system must be suitably qualified. If required, Lincoln GmbH & Co. KG offers you full service in the form of advice, on-site installation assistance, training, etc. We will be pleased to inform you about our possibilities to support you purposefully. In the event of inquiries pertaining to maintenance, repairs and spare parts, we require model specific data to enable us to clearly identify the components of your pump / system. Therefore, always indicate the part, model and series number of your pump / system. Page 4 of 44

5 Safety Instructions Appropriate Use Use the 203 pump only for dispensing lubricants in centralized lubrication systems. The pump is designed for intermittent operation. Misuse Any use of the 203 Pump that is not expressly mentioned in this Owner Manual will be regarded as misuse. If the 203 pumps used or operated in a different manner other than specified, any claim for warranty or liability will be null and void. If personal injury or material damage occurs as a result of inappropriate operation, e.g. if the safety instructions are ignored or resulting from an incorrect installation of the 203 pump, no claims or legal actions may be taken against Lincoln GmbH & Co. KG. General Safety Instructions Quicklub centralized lubrication systems - are designed state-of-the-art. - can be assembled for safe operation. - must be filled regularly without air inclusions with clean lubricant recommended by the manufacturer. Incorrect use may result in bearing damage caused by poor or over-lubrication. Each outlet needed must be equipped with an appropriate check valve. Regulations for Prevention of Accidents To prevent accidents, observe all city, state and federal safety regulation of the country in which the product will be used. Avoid operating by using - not allowed spare parts. - not allowed or polluted lubricants. Installation Any safety equipment already fitted to the machine: - should not be modified or made ineffective. - should only be removed for the purpose of fitting the system. - must be replaced afterwards. Keep Quicklub centralized lubrication systems away from sources of heat. Adhere to the operating temperature. Use only original Lincoln spare parts (see Parts Catalogue) or parts approved by Lincoln. Adhere to: - the installation instructions of the machine manufacturer as regards all drilling and welding procedures. - the specified minimum distances between the bores and the upper/lower rim of the frame or between two bores. Page 5 of 44

6 Safety Instructions, continuation Operation, Repair and Maintenance CAUTION! CAUTION! 4273a00 Pump 203 may be installed only by qualified personnel. The connection (N/L/PE) of the supply voltage must be made according to VDE 0100 and VDE Install a protective and lock out device for isolating and disconnecting the pump 203. Before beginning the installation work, disconnect the electrical supply. WARNING! Failure to observe the safety instructions, e. g. touching electrically charged parts when the pump is opened, or improper handling of the pump 203 may cause serious injury or 4273a00 death. If the values specified in the Technical Data are exceeded, the device may overheat. It may damage the pump 203 and thus impair the electric safety. Repairs should only be performed by authorized personnel who are familiar with the instructions. Defective printed circuit boards should be suitably packed and returned to the factory (see paragraph Printed Circuit Boards, page 28). 1013A94 Danger of squeezing in case of pumps to be filled from the reservoir top: Never put your hand into the open reservoir while pump is running! ATTENTION! Risk of bursting if the reservoir is overfilled! When filling the reservoir by means of filling pumps with a large delivery volume do not exceed the max. filling 1013A94 mark. Lincoln Quicklub centralized lubrication pumps - May be operated only with a fitted pressure relief valve. - must be refilled regularly without air inclusions with clean lubricant recommended by the manufacturer. - operate automatically. However, a regular check (approximately every 2 days) should be made to ensure that lubricant is being dispensed from all lubricant points. CAUTION! Danger of explosion! It is not allowed to use the pump in potentially explosive fields. Disposal Dispose of used or contaminated lubricants as well as of parts that were in touch with lubricant according to the legal regulations pertaining to environmental protection. Make sure to observe the safety data sheets of the lubricants used. Exclusion of Liability Page 6 of 44 The manufacturer of the 203 pump will not accept any liability for damages caused by insufficient lubricant and irregular refilling of pump. caused by the use of contaminated lubricants. due to the use of greases that are not or are only conditionally pumpable in centralized lubrication systems (see page 50ff). chemical or biological changes of the used lubricant. caused by an environmentally inadequate disposal of used or contaminated lubricants or parts that were in touch with lubricants. caused by unauthorized modification of system components. caused by the use of unapproved parts.

7 Pump Types Fig. 1 The different types of pump a95 Pumps 203 The 203 pumps differ from each other only in the design and reservoir size as well as in the type of the electric connection (different plugs with or without electric cable). Reservoir sizes 2 l transparent plastic reservoir 4 l transparent plastic reservoir with/without reservoir cover 8 l transparent plastic reservoir with/without reservoir cover Electric connection For industrial applications the pumps are to be provided simply with a connecting plug for the power supply. All other data such as: motor voltage 24 VDC version of the control unit remote control for triggering an additional lubrication cycle (3A6 1) ) design and number of pump elements design and number of safety valves filling type use of return line connections low-level for grease and low-level for oil 1) can be learnt from the pump type designation code (see page 8) Control unit models 203 The following control units can be used for the 203 pumps: (refer to the respective ) a) external control units PSG 01 PSG 02 (industry) b) integrated control units with adjustable pause and operating times V10 -V13 with adjustable pause and operating times V10-V13 2) for alternate current 120, 230 VAC with metering device monitoring (microprocessor control), M08-M23 with metering device monitoring (microprocessor control) M08-M23 2) VAC 1) Low-level control for oil cannot be combined with control p.c.b.s M08-M23. 2) Refer to the designation on the pump nameplate. Example: P203-2XNBO - 1 K A V10 Also refer to the designation code on page 8. - Refer to the designation on the pump nameplate. Example: P203-2XLBO - 1K6 AC - 3A M08 Also refer to the designation code on page 8. Page 7 of 44

8 Identification Code AC Pump Models P203 with Control p.c.b. M08-M23 Examples of model designations Any pumps combinations other the noted standard pumps can be composed and ordered in accordance with the valid model identification code. P203 Basic pump model for grease or oil with 1-3 outlets and 12 VDC or 24 VDC motor P203-2 X L - 1 K6 - AC - 3A M08 P203-4 X L BO - 1 KR - AC - 3A M10 P203-2 X L - 2 K5 - AC - 3A M12 P203-8 X L BO - 1 K6 - AC - 3A P203-4 Y L BO - 1 K7 - AC - 3A M20 P203-2 X L - 1 K6 - AC - 3A M10 Reservoir design 2 = 2 l transparent plastic reservoir 4 = 4 l transparent plastic reservoir 8 = 8 l transparent plastic reservoir X = Reservoir for grease Y = Reservoir for oil L = Low-level control No indication = standard reservoir (2 liters) BO = Filling from the top Pump elements 1-3 = Number of elements used K 5 = Piston diameter = 5 mm K 6 = Piston diameter = 6 mm K 7 = Piston diameter = 7 mm KR = Pump element, adjustable, piston diameter = 7 mm B7 = Piston diameter = 7 mm (output of K5) S7 = Piston diameter = 7 mm (food industry) Supply voltage AC = VAC ±10% (50-60 Hz ±5% with 24 VDC direct current motor) Number of electric connecting possibilities (on pump housing only) 3A = 3 connections: - power supply (only cube-type plug), left bottom - illuminated push button + low-level control (quarter turn type plug), left top - piston detector (bayonet plug), right top (4/4) Type of connection 1 = Cube type plug, DIN 43650, type of construction A 6 = Quarter turn type plug, 7/5-core, DIN (M08-M23) Connection outside of the pump 15 = Quarter turn type socket with 10 m cable, 7/5-wire Control p.c.b. 12V / 24 V M08-M23 = with microprocessor control (various adjustments, see combination of the jumper-positions, page 35) Page 8 of 44

9 Description Fig. 2 Pump components 1 - Reservoir 2 - Pump element 3 - Pressure relief valve 4 - Filling nipple, system Emergency lubrication possible 5 - Plug, piston detector 6339b Filling nipple, pump 7 - Printed circuit board, mounted 8 - Plug, power supply 9 - Plug, illuminated pushbutton for additional lube cycle 10 - Return line connection The Quicklub 203 central lubrication pump is a compact multiline pump consisting of the following components: - Housing with integrated motor - Reservoir with stirring paddle - Printed circuit board - Pump element - Pressure relief valve - Filling nipple - Electrical connection parts can drive up to 3 pump elements operates according to lubrication cycles (pause and operating times) can be equipped with a low-level control can supply up to 300 lubrication points depending on the line lengths is designed for the automatic lubrication of the connected lubrication points is designed for the delivery of greases up to NLGI 2 at temperatures from - 25 C to 70 C or of mineral oils of at least 40 mm²/s (cst) can be used at low temperatures down to - 40 C. During the operating time the pump dispenses lubricant to the connected lubrication points via one or several metering devices. Low level control Pump 203 is equipped with a low-level control for grease or oil. The following versions are available: - Low-level control for grease to be combined with integrated control p.c.b. M08-M23, see fig. 3 - Low-level control for oil not to be combined with integrated control p.c.b. - When the reservoir is empty, an electrical low-level indication will be given. 6340b Low-level control (see also fig. 19, page 15) Fig. 3 Quicklub central lubrication pump, 2 l reservoir Page 9 of 44

10 Mode of Operation Pump Elements with fixed Lubrication output The electric motor drives the eccentric (pos. 1, fig. 5a and 5b). During the operating time: - piston 2 sucks in lubricant from the reservoir, see fig. 5a. - piston 2 dispenses the lubricant to the connected lubrication points via the metering device, see fig. 5b. The following designs are available: - Piston diameter, K mm Lubricant output... approx. 2 cm³/min - Piston diameter K6 (standard)... 6 mm Lubricant output... approx. 2.8 cm³/min Fig. 4 Pump element 1 - Piston 4 - Check valve 2 - Return spring Piston diameter, B mm Lubricant output... approx. 2 cm³/min - Piston diameter, K7, S mm Lubricant output... approx. 4 cm³/min IMPORTANT The lubricant output listed refers to grease of NLGI grade 2 measured at 20 C, backpressure 100 bar, nominal voltage 12/24 V. Any differing pressures or temperatures result in different lubricant outputs. Any system design must be based on the above values compete. 1003b04 Fig. 5 a) Pump element sucks in lubricant b) Pump element dispenses lubricant 1 - Eccentric 2 - Piston 3 - Return spring 4 - Check valve 1004b04 Pump element B7 with bypass check valve 6251b b04 Fig. 6 Page 10 of 44 Pump element B7 Pump element B7 suits especially applications in contaminated environments as the supplied lubricant is passing through a bypass bore (pos. 2) on the check valve (Pos. 1). The output is 2 cm³/min. Fig Check valve 2 - Bypass 3 - Pump piston 4 - Return spring Sectional diagram - pump element B7

11 Mode of Operation, continuation Pump Elements with fixed Lubrication output, continuation Check valve The check valve - closes the pressure line during suction stroke. - prevents the lubricant from flowing back to the housing or reservoir. Fig. 8 Hydraulic diagram of the pump 1164b Reservoir with stirring paddle 2 - Pump 3 - Check valve, spring-loaded 4 - Pressure relief valve R - Return line p - Pressure line Arrangement of the pump elements If several pump elements are to be installed, the installation arrangement shown in Fig. 9 must be adhered to. If there is only one pump element, it can be installed in any position. Standard position is no. 3. If there are two elements, install one in position 3 and the other in position 1. Fig. 9 Arrangement of the pump elements 1163a95 Pump Elements with adjustable Lubricant output The mode of operation (suction and supply phase) is the same as that of the pump elements with an invariable lubricant output. The lubricant outputs are adjustable from 0.04 to 0.18m 3 /stroke, or 0.7 to 3cm 3 /min. The pump elements are factory-adjusted to the maximum lubricant output; the adjusting dimensions S should be 29 ± 0.1 mm (see fig. 11 and 12, page 12). 4158a99 Fig. 10 Adjustable pump element Page 11 of 44

12 Mode of Operation, continuation Fig. 11 Sectional view: adjustable element 1 - adjusting spindle SW 16 (SW ~ with over flats) 2 - counternut SW pump element body 4 - gasket 5 - pump cylinder 6 - control piston 7 - delivery piston S - setting dimension 4159a98 Setting of adjustable pump elements Unscrew the coupling nut for fixing the pressure relief valve. Loosen counter nut (pos.2 1) ) while holding in position pump element body (pos.3) by means of a second wrench. Change the position of the adjusting spindle (pos.1) by means of a wrench. The dimension S (fig. 11) for the desired lubricant output can be ascertained by using the supply diagram (fig. 12). Retrofit adjustment of max. lubricant output Fig. 12 Supply diagram A - Lubricant output cm 3 /min B - Lubricant output cm 3 /stroke S - Setting dimension Page 12 of a99 In order to ensure that the lubricant output setting will be as exact as possible, first the actual dimensions S of the max. lubricant output must be ascertained as follows. The measured difference from the nominal value 29 must be considered for all other settings values (e.g. ± 0.1). Unscrew the adjusting spindle (pos.1 1) ) from the pump element body (pos.3) until S is approx. 30 mm. Screw counter nut (Pos.2) onto stop collar of the adjusting spindle (pos.1). Screw adjusting spindle (pos.1) with counter nut (pos.2) into pump element body (pos.3) until stop. 1) All indications of positions refer to fig. 11.

13 Mode of Operation, continuation Retrofit adjustment of min. lubricant output Before the pump element can be adjusted to a small lubricant output, the dimension S for max lubricant output must be ascertained, and the difference from the nominal value 29 must be transferred to any desired settings between Dimension S must be adjusted to the desired value in accordance with the delivery diagram (fig. 12, page 12). At maximum setting S is 29 ±0.1 mm. Pressure relief valve without grease return IMPORTANT Each pump element must be secured with a pressure-limiting valve. The pressure relief valve is not contained in the scope of supply of the pump 203. Therefore it is to be ordered separately (see Spare Parts Catalogue). The pressure relief valve - limits the pressure build-up in the system. - opens, if the specific overpressure is reached. Fig. 13 Pressure relief valve 6342b04 - is to be selected according to the requirements to the lubrication plant (see different opening pressures; 200, 270, 350 bar). If lubricant is leaking at the pressure relief valve, this indicates that the system is malfunctioning. Despite existing fault monitoring devices a regular visual and function control must be carried out on the lubrication system. Between a malfunction (blockage) and the following fault indication (lubricant leakage; monitoring intermittent LED display) there may be a longer time delay. The duration of the delay depends on the type and length of the lines, the type of lubricant, the ambient temperature and other influences. Pressure relief valve with grease return (optional) If the system is blocked, grease will leak from the pressure relief valve. This grease quantity is returned to the reservoir. Fig. 14 Pressure relief valve with grease return 6341b04 Page 13 of 44

14 Mode of Operation, continuation Pressure relief valve, continuation Pressure relief valve with grease return (optional), continuation Fault indication In the case of a blockage in the system, the grease pushes out the red pin at the pressure relief valve, thus indicating that there is a fault. Fig. 15 Fault indication in the case of a blockage 6343b04 Return Line Connection The lubricant quantities, which cannot be dispensed by the metering device, must be returned to the pump via the return line connection (fig. 16). Fig. 16 Return line connection Low Level Control Float magnetic switch for oil Operating mode Float magnetic switches are equipped with hermetically sealed reed contacts. The reed contacts are activated by the magnetic field of a ring solenoid included in the float totally free of wear and without contact. The only movable component of the float magnetic switch is the float that moves up and down with the liquid reliably on the slide tube. Fig. 17 Page 14 of 44 Connection diagram, low level control for oil 1202a99 Technical Data Maximum switching capacity... max. 60VA Maximum switching voltage - with power supply AC... max. 230 V Current switched... 3 A

15 Mode of Operation, continuation Low Level Control, continuation Contact protection measures Fig. 18 Contact protection measures 1 - Electromagnetic switch 2 - RC element 3 - Diode 4 - Load For grease 6295b04 Fig. 19 Parts of the low level control 1 - Guiding plate with round solenoid (on stirring paddle) 2 - Electromagnetic switch (at stirring paddle) 3 - Control cam A - Rotating direction B - Lubricant resistance The above-mentioned switching parts must not be used with fluid grease. In this case, use a float magnetic switch, see below low-level control for oil (see fig. 19, page 14). 1201a95 The low level for oil does not interfere in the control. A potential-free contact is available for monitoring purposes. In case of a low-level indication, switch the pump off. Reservoir filled The stirring paddle rotates clockwise (Pos. A 1) ) during the operating time. When the stirring paddle rotates, the pivoted guiding plate with the round solenoid (pos.1 1) ) is pressed backwards by the resistance of the lubricant (Pos. B 1) ). The solenoid moves towards the pivot of the stirring paddle. An activation of the solenoid switch (Pos.2 1) ) cannot occur. Control cam item (pos.3) guides the round solenoid with the pivoting guiding plate automatically outwards, in the direction of the reservoir wall. After the lubricant has left the control cam, it flows against the guiding plate, thus displacing the solenoid again onto the center of rotation of the stirring paddle. 1) All indications of positions refer to fig. 19. Reservoir empty During the rotating motion of the stirring paddle there is no backpressure from the lubricant. The guiding plate with the round solenoid no longer moves towards the center of rotation of the stirring paddle. After control cam (pos. 3 1) ) has been overtravelled the solenoid remains in the outer position and overruns electromagnetic switch (pos. 2). The solenoid activates the electromagnetic switch contact-free, thus triggering a low-level signal. 1) All indications of positions refer to fig. 19. The flashing signal starts only after the solenoid has activated the electromagnetic switch 6 times contact-free. Page 15 of 44

16 Printed Circuit Boards M08-M23 1) 1) M08-M23 are names for the respective version of the printed circuit board. It is part of the pump type designation on the identification plate at each pump. (see tab. Jumper-Configuration, page 35). Fields of Application Pump Voltage [V] Control unit Setting ranges Part-no. Applications 203 Power supply AC: VAC integrated M08-M23 P: 4 to 60 minutes P: 1 to 15 hours Ü: 5 or 30 minutes P - Pause time range Ü - Monitoring time The applications of the progressive systems are various. There is therefore a control unit available for each individual application. Installation position of the printed circuit board (p.c.b.) The printed circuit boards are integrated in the pump housing. Fig. 20 Printed circuit board integrated in the housing 6344b control p. c. b. 2 - power supply p. c. b. Page 16 of 44

17 Printed Circuit Boards M08-M23, continuation Advantages The centralized lubrication system is monitored and mainly differs in the way faults are evaluated and displayed. The following faults are displayed depending on the version of the p.c.b.: Version M08-M15: Faults on motor and lamp, lapsing of the operating time, blockage in the system, low-level indication with different intermittent signals Version M16-M23: General signal for readiness for service The following functions and operations are monitored and indicated as a fault in the case of a malfunction: Pump Function of the driving motor Interruption of power supply to the motor Pump element does not supply Check valve in the pump element is defective Reservoir empty Fault indication will be effected as soon as reservoir is empty even if pump element is still surrounded by lubricant. System Lubrication point or metering device blocked Main line leaking (from pump to the monitored metering device) Air bubbles in the grease Lubrication circuit 1 and/or - if any- lubrication circuit 2 malfunctioning Start up When switching on the power supply (VAC) the control unit of the pump is ready for service. The machine contact (MC) is to control the further functioning and its adaptation to the requirements of the lubrication points. If no machine contact is available, the black and the red line must be connected externally (see broken line Connecting Diagram, page 34). The functional sequence is then controlled by the power supply. Page 17 of 44

18 Printed Circuit Boards M08-M23, continuation Applications Lubrication procedures should be carried out depending on the number of machine operating hours completed. Additional lubrication procedures are always possible provided the power supply (VAC) is switched on. When switching on the machine contact, the control unit is ready for service. From now on the control unit takes care of the lubrication procedure and the monitoring of the centralized lubrication system. Version M08-M23 Fault indications:.. depending on the fault by means of different intermittent frequencies Version M16-M23 Signal for readiness for service:.. Provided the power supply is switched on and there is no fault in the system, an external relay picks up or a control lamp is on. Operating states (M16-M23 only) Control p. c. b. Voltage ON Readiness for service Malfunction Low level, malfunction Fig. 21 Control p. c. b a Page 18 of 44

19 Control Unit Operation Fig. 22 Time sequence diagram t B - Working hours t P - Various pause times T - Lubrication cycle T1 - Stored pause times T2 - Operating times 1059a95 The proceeding of working hours and pause times is started and stopped via the machine contact. The control unit automatically controls the proceeding of pause and operating times of the centralized lubrication pump 203 (in dependence of the machine operating hours t B, see fig. 22). A lubrication cycle consists of one pause time and one operating time. Once the pause time has elapsed, the operating time starts running. This lubrication cycle is repeated permanently after the machine has been put into operation. During the operating time the pump element delivers the lubricant to the lubrication points via progressive metering devices Pause time The pause time - determines the frequency of the lubrication cycles within a working cycle. - is started and stopped with the power supply via the machine contact. - is adjustable. When the supply voltage is switched off, the pause times that have already elapsed as well as the momentary operating conditions (faults) are stored by an electronic memory (EEPROM). This continues until the time set on the blue rotary switch (see fig. 26, page 21) is reached. After the supply voltage is switched on again, the control unit operates from the point where it had been interrupted. If the setting is modified within the pause time, the printed circuit board takes over the new value only at the end of the operating time. The pause time setting may be different for each application. It must be adjusted in accordance with the respective lubrication cycles (see paragraph To set the pause time, page 21). Operating time A piston detector (initiator, fig. 23) that has been installed on a metering device instead of a piston closure plug monitors and brings the pump operating time to a close after all the pistons of this metering device have dispensed their lubricant quantity. The operating time depends on the system s lubricant requirement and on the location of the piston detector (either on the main metering device or on the secondary metering device). Fig. 23 Piston with mounted detector If two lubrication cycles are monitored, the operating time ends after the two piston detectors have transmitted their signal to the printed circuit board. The operating time always elapses completely even if the machine contact or the driving switch is switched off. Page 19 of 44

20 Control Unit, continuation Mode of Operation, continuation Monitoring time A fixed monitoring time of maximum 5 or 30 minutes (depending on the jumper position, page 35) runs in parallel to the operating time. Normally, the monitoring time ends at the same time as the operating time. If there is no switching off signal from the piston detector to the printed circuit board within 5 or 30 minutes, a fault signal will occur. M08-M15: The signal lamp flashes with the corresponding flashing frequency (see page 23, paragraph Signal output ). Fig. 24 Monitoring ranges, jumper positions 1 - Jumper for monitoring time 5 min 5 minutes 30 min 30 minutes 2 - Jumper for monitored lubrication cycles 1 O 1 lubrication cycle 2 O 2 lubrication cycles a If the operating time exceeds 5 minutes, the monitoring time can be changed from 5 to 30 minutes by replugging the jumper (see also page 35). If there are two monitored lubrication cycles, the jumper must be plugged from 1O to 2O (see also page 35). Time storage When switching off the operating voltage, the times already expired are saved for an unlimited duration. When the power supply is switched on again the printed circuit board continues to operate from the point where it had been interrupted. Page 20 of 44

21 Control Unit, continuation Time Setting To set the pause or operating time, remove the cover on the pump housing. IMPORTANT After having set the pause time or operating time, screw the cover on the pump house again. If the housing is not closed, water may enter. Damages resulting from this are not included in our warranty. 6345b04 Fig. 25 The cover to the p. c. b. Setting of the pause time The pause time can be set with the blue rotary switch to 15 stages. The jumper above the blue rotary switch (see fig. 26) is to set the desired time range (4-60 minutes or 1-15 hours). Using tweezers or pointed pliers the setting can be carried out also with installed printed circuit board. Switch positions 0 and 1are identical and correspond to the shortest adjustable time. Fig. 26 Pause time rotary switch a Switch position 0/ A B C D E F Minutes Hours Factory Setting Pause time jumper position hours rotary switch position hours Monitoring time jumper position... 5 minutes Monitored lubrication cycles jumper position... 1O Fig. 27 Preselection of time ranges, jumper position a Combination of the jumper positions see page 35. Page 21 of 44

22 Control Unit, continuation Functional Check and Fault Indication Functional check when switching on Each time the machine contact (external contact) is switched on, a functional check of the drive motor and signal lamp (only M08-M15) takes place automatically During the functional check the motor is switched on for 0.1 seconds (the stirring paddle slightly rotates) and the signal lamp lights up for 2 seconds. If there is a fault - the signal lamp flashes (M08-M15). - the LED is not lit and the pump stops operating (M16-M23). See page 26, paragraph Signal Output a LED display (fig. 33) indicates the same operating state as the external signal lamp. Fig. 28 LED for monitoring time and failure display Operational Test / To Trigger an Additional Lubrication Cycle To check the function of the pump it is possible to perform an operational test: - Switch on the power supply. Whether tension rests against the p.c.b., is recognizable from the bright left LED (pos. 1). - Switch on the machine contact. - Press button (pos. 4 or at the switchgear cabinet) until the right LED (pos. 3) is lit. LED 1 is lit...pump ready for operation LED 3 is lit... Pump is ON LED 3 is not lit... Pump disturbed Fig. 29 LED of the p.c.b. 1 - LED, left hand: power supply 2 - rotary switch: pause time 3 - LED, right hand: indication of operation 4 - pushbutton for additional lubrication cycle a Additional lubrication cycles are possible at any time by actuating the pushbutton (pos. 4). Page 22 of 44

23 Control Unit, continuation Functional Check and Fault Indication, continuation Signal Output (M08-M15) Intermitted flashing signal (B) The signal output takes place with the right LED and is implemented as follows: Jumper B/D mounted Fig. 30 p.c.b. with mounted jumper B/D a System Motor check Operating time Fault LED (see pos. 3, fig. 29, page 22) is lit for approx. 2 seconds LED is lit Flashes according to the present fault indication with different frequency (see paragraph Functional Check when switching on, page 22). Signal Output M16-M23 Permanent signal (D) The signal output via external relay is carried out as follows: Jumper B/D removed System External relay 1) LED 2) (see pos. 3, fig. 29, page 22) Ready status (no present disturbance) Fault 1) Relay has picked up 2) LED is lit permanently 1) Relay dropped 2) LED is not lit, central lubrication system does not run Fig. 31 p.c.b. without jumper B/D Acknowledging receipt of a malfunction (M08-M15) Press pushbutton (see fig. 32 or pos. 4, fig. 29, page 22) (<1 second) to acknowledge receipt of a malfunction. Any acknowledged fault remains stored even after the machine contact has been switched off. Upon switching on again, the signal lamp flashes again in accordance with the fault Fig. 32 Acknowledging receipt Page 23 of 44

24 Control Unit, continuation Functional Check and Fault Indication, continuation Function of the pushbutton for additional lubrication cycles The following functions can be performed with the pushbutton (see pos. 4, fig. 29, page 22): In ready status: - triggering an additional lubrication cycle - press pushbutton for over 2 seconds (> 2 seconds). In trouble: - fault acknowledgement < 1 second. - in the case of a fault, switch on pump again by pressing pushbutton (> 2 seconds). LED function (M08-M15) LED function (M16-M23) 1052b95 Fig. 33 Indicated operating states (M08-M15) A - Indication of operation or acknowledged fault B - Fault indication The signal lamp or the LED (pos. 3, fig. 29, page 22) indicates the operating state of the centralized lubrication system. The faults are indicated by different flashing frequencies of the signal lamp or the LED (see paragraph Signal Output M08-M15, page 23). 1162a95 Fig. 34 Indicated operating states (M16-M23) A - Indication of function B - Fault indication The LED (pos. 3, fig. 29, page 22) indicates the operating state of the centralized lubrication system. Possible operating conditions: - System ready... LED is lit permanently - System disturbed... LED is not lit Page 24 of 44

25 Control Unit, continuation Functional Check and Fault Indication, continuation Fault Indication In the case of a malfunction the piston detector (initiator, fig. 23, page 19) can no longer record the piston movements and therefore, cannot switch the pump off. M08-M15 Due to the monitoring time that runs in parallel to the operating time, the printed circuit board switches off the pump at the end of the monitoring time. A fault signal occurs. The signal lamp is flashing. The pump no longer starts automatically (see paragraph To Remedy to a Fault, page 26). Fault: A Drive motor defective such as: If the motor does not run when the driving switch or machine contact is switched on or if the feed line to the motor is damaged, the signal lamp flashes after 2 seconds as follows: Flashing frequency 1 second ON 1 second OFF B - D Malfunctions such as: blocked lubrication point(s) blocked metering device(s) interruption in the main line leading to the metering device equipped with a piston detector air in system reservoir empty (only if the pump is not equipped with an optional low-level control) The above-mentioned faults cause the pistons in the monitored metering device to stop. The signal lamp indicates the respective fault signal with the following flashing frequencies: B Lubrication circuit 1 malfunctioning Flashing frequency 0.5 seconds ON 1 second OFF Fig. 35 Flashing frequencies in the case of malfunctions (M08- M15) A - Drive motor defective B - Lubrication circuit 1 malfunction C - Lubrication circuit 2 malfunction D - Lubrication circuit 1 and 2 malfunction E - In the case of low-level control: reservoir empty F - Fault acknowledged (maintained lightening) 1053b95 C Lubrication circuit 2 malfunctioning Flashing frequency 1 second ON 0.5 seconds OFF D Lubrication circuit 1 and 2 malfunctioning Flashing frequency 2 seconds ON 2 seconds OFF E Reservoir empty This malfunction is indicated via the LED only if a low-level control is installed: Flashing frequency 0.5 seconds ON 0.5 seconds OFF Page 25 of 44 The low-level signal is converted into a flashing signal with the a.m. frequency only after 6 motor revolutions.

26 Control Unit, continuation Functional Check and Fault Indication, continuation Fault Indication, continuation M16-M23 Fig. 36 Readiness for service and fault indication (M16-M23) A - Readiness for service B - Fault indication 1162a95 If any of the following faults occurs, the LED is extinguished, the external relay drops out and the pump stops operating. Faults Drive motor defective: - The external relay drops out, the LED is extinguished after 2 seconds. The following malfunctions are not indicated as individual faults, such as - blocked lubrication point(s) - blocked metering device(s) - interruption in the main line leading to the metering device equipped with a piston detector - air in system - reservoir empty Reservoir empty: - The LED is extinguished. - The operating time comes to a close. - The pump no longer starts automatically (see paragraph To Remedy to a Fault ). To Remedy a Fault IMPORTANT If there has been any fault, the pump will not start automatically after the elimination of that fault. It must be switched on, i.e. an additional lubrication cycle must be triggered. In the case of a fault, check whether the central lubrication pump and the connected system are malfunctioning. Eliminate the cause of the fault (see chapter Troubleshooting, page 30 and 31). Switch the pump on again by triggering an additional lubrication cycle (see page 22). M08-M23: When the fault is eliminated, the signal lamp will extinguish at the end of the lubrication cycle. M16-M23: Once the fault is eliminated, the LED will be lit again at the end of the lubrication cycle. Page 26 of 44

27 Maintenance, Repair and Tests Maintenance The maintenance is essentially limited to refilling the reservoir with clean lubricant in good time. However, check regularly whether the lubricant is really dispensed to all the lubrication points. Also check the main lines and lubricant feed lines for damage and replace them, if necessary. Whenever work is done on the centralized lubrication system, particular attention should be paid to absolute cleanliness. Dirt in the system will cause prob- lems. For cleaning the system use benzine or petroleum. Do not use tri-, perchloroethylene or similar solvents. Also do not use polar organic solvents such as alcohol, methylacohol, acetone or similar Pump Filling 2 l, 4 l, 8 l - reservoirs Fill the reservoir up to the Max. mark via the filling nipple, if any, or via the upper filling opening. It is possible to use greases up to penetration class NLGI 2 or mineral oils of at least 40 mm²/s (cst). IMPORTANT The grease or oil must be free from impurities and must not be liable to change its consistency in the course of time. CAUTION! Fig. 37 Fill pump reservoir 6347b A94 Danger of squeezing in case of pumps to be filled from the reservoir top: Never put your hand into the open reservoir while pump is running! CAUTION! Risk of bursting if the reservoir is overfilled. 1013A94 When filling the reservoir by means of pumps with a large delivery volume do not exceed the max. filling mark. If the reservoir has been completely emptied, the pump may require until 10 minutes before it operates with its full output. Page 27 of 44

28 Maintenance, Repair and Tests, continuation Repair Pump Use only original Lincoln spare parts for repair on the pumps. Replace pump element The pump should be returned to the factory for warranty work or major repairs. Remove the pressure relief valve from the pump element. Unscrew the pump element. IMPORTANT Take care that the piston, the pull-back spring and the washer are not left lying in the grease, otherwise the reservoir must be disassembled in order to remove these pieces. Fig. 38 Replace pump element 5026a96 IMPORTANT Do not leave the piston, spring and washer in the housing as they may block the motor. Pump element with adjustable lubricant output is set to the same output as the old pump element. Install a new pump element and a new sealing ring. Printed Circuit Boards Note all jumper positions of the defective p.c.b. (see paragraph Combination of the Jumper Positions, page 35). Defective printed circuit boards should be suitably packed and returned to the factory. If a control p.c.b. must be replaced, always a new p.c.b. type M08 will be delivered. Configure at the new p.c.b. the noted jumper positions of the old p.c.b. Page 28 of 44

29 Maintenance, Repair and Tests, continuation Tests Operational Test / To Trigger an Additional Lubrication Cycle To check the pump operation it is possible to perform an additional test. Refer to the of the respective printed circuit board (see paragraph Operational Test / To Trigger an Additional Lubrication Cycle, page 22). To Check the pressure relief valve 1st option Connect the pressure gauge (0-600 bar; psi) to the pressure relief valve (fig. 14 to 16, page 13 and 14). Trigger an additional lubrication cycle. 2nd option Connect the manual pump of the pressure and checking set to the safety valve and check the opening pressure by means of the manual pump. The safety valve should open at a pressure of 200, 270 or 350 bar depending on its design. IMPORTANT Do not connect the pressure gauge directly to the pump element. High pressure may exceed the above-mentioned range, causing the motor to stall. The motor is designed in such way that it can stall for about 30 minutes without being damaged. Fig. 39 To check the pressure relief valve 6348b Hose line, min. length 1m 2 - T-piece 3 - Pressure gauge 4 - Relief cock Functional Check of the p.c.b. See paragraph Functional Check and Fault Indication, page 22. Page 29 of 44

30 Troubleshooting The pump operation can be checked from the outside by observing whether the stirring paddle is rotating (e.g. by triggering an additional lubrication). In addition, disturbances of the pump can be seen on the p.c.b. (see chapter Functional Check and Fault Indication, page 22). Fault: Pump motor does not run Cause: Power supply interrupted Remedy: 4273a00 Check the power supply and fuses. If necessary rectify the fault and/or replace the fuses. Check the line leading from the fuses to the pump plug. Electric motor defective Check the power supply to the motor. If necessary, replace the motor. p.c.b. defective Check the function of the p.c.b. (see paragraph Operational Test / To Trigger an additional lubrication cycle, page 22). If necessary replace the p.c.b.. Fault: The pump motor runs permanently during the monitoring time (5 or 30 minutes) Cause: Remedy: Piston detector (initiator) defective Disconnect the main line leading to the monitored metering device. Unscrew the piston detector. Check the piston detector. For this, insert a metallic pin into the borehole of the detector. Let it there over 2 seconds and then remove it. If the pump is not switched off afterwards, check the cable connections to the pump. If necessary, replace the piston detector along with the connector. Cable connection of the piston detector to the pump interrupted Check the cable connections to the pump. If necessary, replace the piston detector with the connector. p.c.b. defective Check the function of the p.c.b. (see paragraph Operational Test / To Trigger an additional lubrication cycle, page 22). If necessary, replace the p.c.b.. Page 30 of 44

31 Troubleshooting, continuation Fault: The pump does not deliver the lubricant Cause : Remedy: If a lubricant low-level is available, the low level is indicated by the flashing light of the signal lamp. Reservoir empty Fill up the reservoir with clean grease or oil. Allow pump to run (trigger an additional lube cycle, see page 22) until the lubricant penetrates from all the lubrication points. Depending on the ambient temperature and/or sort of lubricant it may take 10 minutes of operation before the pump elements reach their full lubricant output. Air bubbles in the lubricant Trigger an additional lubrication cycle (see page 22). Loosen the outlet fitting or the main line at the pressure relief valve. The lubricant must penetrate without air bubbles. When push-in type fittings are used, the high-pressure plastic hose that is under pressure cannot be easily disconnected from the safety valve. For this purpose, loosen the closure plug or the filling nipple, if any, on the pressure relief valve in order to relieve the high-pressure hose. Unsuitable lubricant has been used Replace the lubricant. See lubricant list (see pages 42 and 43). Suction hole of the pump element clogged Remove the pump element. Check the suction hole for foreign particles. If there are any, remove them. Pump piston worn Replace the pump element. Check valve in the pump element defective or clogged. Replace the pump element. Page 31 of 44

32 Technical Data PUMP Admissible operating temperature C to 70 C 1) Number of outlets... 1, 2 or 3 Reservoir capacity... 2 l, 4 l, 8 l Refilling... via hydraulic lubrication fitting or from top Lubricant... greases up to NLGI grade 2...& mineral oils of at least 40 mm²/s (cst) at 40 C Class of protection... IP6K 9K acc. to DIN T9 1) The pump is designed for the above mentioned temperature range. The lubricants used must still be pumpable at the temperatures mentioned above. For lower temperatures, use low-temperature lubricants. In case of doubt, consult the lubricant manufacturer. MOTOR Speed... approx. 17 U/min Pump element with fixed lubricant output Piston diameter, K mm - Lubricant output... approx. 2 cm³/min Piston diameter, (Standard) K mm - Lubricant output... approx. 2.8 cm³/min Piston diameter, B mm - Lubricant output... approx. 2 cm³/min Piston diameter, K7, S mm - Lubricant output... approx. 4 cm³/min max. operating pressure bar Connection thread... G ¼ - suitable for tube DIA... 6 mm Pump element with adjustable lubricant output KR to 0.18 cm³/stroke to 3 cm³/min Connection thread... G ¼ - suitable for tube DIA... 6 mm - suitable for tube DIA... 8 mm IMPORTANT The lubricant output listed refers to grease of NLGI grade 2 measured at 20 C, backpressure 100 bar, nominal voltage 12/24 V. Any differing pressures or temperatures result in different lubricant outputs. Any system design must be based on the above values. TORSION TORQUES Install pump Nm Electric motor on housing Nm Pump element in housing Nm Closure plug in housing Nm Return line connector in housing to 12 Nm WEIGHTS The weights below include the following individual weights : - Pump kit with one pump element, safety valve, grease filling (0.75 kg, 1.5 kg) - Packing (cardboard box) - Attaching parts - Operating Instructions 2 l reservoir, standard design (0.75 kg) - Pump 203 without connection cable kg - Pump 203, version 1A kg - Pump 203, version 2A kg 4 l reservoir, standard design (1.5 kg) - Pump 203 without connection cable kg - Pump 203, version 1A kg - Pump 203, version 2A kg 8 l reservoir, standard design (1.5 kg) - Pump 203 without connection cable kg - Pump 203, version 1A kg - Pump 203, version 2A kg In the case of pump versions deviating from those mentioned, add the weights of the following components to the mentioned weights: - per pump element kg - per pressure relief valve kg - 10 m monitoring cable, 5-wire (microprocessor) 2A kg - 10 m monitoring cable, 4-wire (microprocessor) 2A kg - Connection cable with piston detector kg - Reservoir version Filling from top (only 2 l) 3) kg - 2 l flat-type reservoir kg 3) The 4l and 8l reservoirs have the standard design filling from top. Also available with reservoir closed on the top. PRESSURE RELIEF VALVE SVETVT-350-G 1/4A-D SVETVT-350-G 1/4A-D Page 32 of 44

33 Technical Data, continuation Electrical Data PUMP Input AC Input voltage VAC ±10% ; 50/60 Hz ±5% Input current ma at 230 VAC Starting current impact... < 18 A Fuse... T 1,25 A/250 V intern Operating Mode IMPORTANT Suitable for interval operation only, not for permanent operation! If internal fuse has to be replaced, use only the original type. Operating voltage > 120 VAC: - max. operating time minutes - min. pause time... 4 minutes Operating voltage < 120 VAC: - max. operating time... 8 minutes - min. pause time minutes Output Output voltage, internal VDC ±1% Protection and monitoring Current limiting... resistant to sustained short circuit Overload-proof... yes Idling-proof... yes Mains buffering time... > 15 ms at 230VAC Safety VDE 085 / / EN / IEC 950, EN Output... safety extra-low voltage (SELV) Class of protection... class 1 Degree of protection... IP6K9K (installed in pump housing) Discharge current... < 0,25 ma (47-63 Hz and U ON max.) EMC Radio interference suppression... VDE 0875 T 11, EN class A Emitted interference... acc. to EN 50081/2 Noise immunity... acc. to EN 50082/2 The emitted interference meets the requirements for the industrial sector, if used in the residential sector this may possibly lead to interference. Motor DC gear motor (interference-suppressed) - Operating voltage VDC - Max. current input... 3 A - Speed... approx.17 U/min PRINTED CIRCUIT BOARD Rated voltage VDC Operating voltage... 9 to 30 V Residual ripple in relation - With the operating voltage... ±5% acc. to DIN Output motor... transistor 7A / short-circuit proof Reverse voltage protection... Operating voltage inputs... are protected against polarity reversal Temperature range C to 70 C - Output fault / readiness for service...transistor 3A / short-circuit proof Class of protection: Printed circuit board installed in housing... IP 6 K 9 K In order to protect the printed circuit board against condensation, it has been covered with a protective varnish. All the printed circuit boards comply with the EMC (Electromagnetic compatibility) guidelines for road vehicles acc. to DIN T1, 3 and 4. Emitted interference... acc. to EN / and... acc. to EN / 01 Noise immunity... acc. to pren / 1994 Time Setting - Pause time either... 4, 8, 12, minutes or... 1, 2, 3, 15 hours - Operation time is switched off via the piston detector - Monitoring time either... 5 minutes or minutes - Monitored lubrication cycles either... 1 cycle or... 2 cycles - Factory setting Pause time... 6 hours Monitoring time... 5 minutes Monitored lubrication cycles... 1 cycle Page 33 of 44

34 Technical Data, continuation Connection Diagram Consider the safety instructions, page 6! Fig. 40 Connection diagram Quicklub 203 with monitoring of the divider blocks (industry), connectors AMP 6373a04 Page 34 of 44

35 Technical Data, continuation Combination of the jumper positions Survey Possibilities of preselection Setting Connection of the supply voltage only terminal 15 terminal Signal indication in the case of faults Pause time ranges Signal output h min intermittend permanent Monitoring time ranges (min) Number of the monitored lubrication circuits Jumper position Combination number 1175a a a a a a a a a a95 M08 X X X X X M09 X X X X X M10 X X X X X M11 X X X X X M12 X X X X X M13 X X X X X M14 X X X X X M15 X X X X X M16 X X X X X M17 X X X X X M18 X X X X X M19 X X X X X M20 X X X X X M21 X X X X X M22 X X X X X M23 X X X X X Fig. 41 Schematic view of the p.c.b. Page 35 of a95

36 Technical Data, continuation Terminals of the p.c.b lubrication cycle 1 and low level control motor external signal lamp additional lubrication machine contact + - power supply Fig. 42 Terminals of the p.c.b. Attaching Boreholes of the 2 l-, 4 l- and 8 l- pump 1171b03 Fig. 43 Attaching Boreholes of the 2 l-, 4 l- und 8 l- pump Page 36 of 44 Thighten pump models wih 2 l - flat, 4 L - and 8 L reservoir with three fastening screws (see pt. R 9,5).