Lubricator LUC 125

Revision: 032022-D064493

Operating manual

Lubricator LUC+125

Operating manual Lubricator

Revision: 03 2022-D064493

Revision Date Comment Section

01 26.06.2018 First edition All02 26.07.2018 Technical data All03 30.07.2019 Signal length 8.1.1

Revision history

Sales WITTENSTEIN alpha GmbH Walter-Wittenstein-Strasse 1 D-97999 Igersheim Phone: +49-(0)7931-493-0 Fax: +49-(0)7931-493-10942 E-mail: [email protected]

Service contact

In case you have technical questions, please contact:

WITTENSTEIN alpha GmbHCustomer ServiceWalter-Wittenstein-Strasse 1D-97999 Igersheim

Phone: +49 7931 493-10900Fax: +49 7931 493-10903E-mail: [email protected]

Copyright

The rights to the layout and corporate design are held by © WITTENSTEIN alpha GmbH 2019The rights to the contents and texts are held by © DLS Schmiersysteme GmbH 2019This documentation is protected by copyright.All rights, including those to the photomechanical reproduction, duplication and distribution by means of special processes (e.g. data processing, data carriers and data networks), including extracts, are held by WITTENSTEIN alpha GmbH and DLS Schmiersysteme GmbH.Subject to technical changes and changes of contents.


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Inhalt1 About this manual 2

1.1 Signal words 21.2 Safety symbols 31.3 Layout of the safety instructions 31.4 Information symbols 3

2 Safety 42.1 EC/EU directive 42.2 Hazards 42.3 Personnel 42.4 Intended use 42.5 Reasonably foreseeable misuse 42.6 Warranty and liability 52.7 General safety instructions 5

3 Functional description 63.1 Type plate 73.2 Marking 73.3 Ordering code 73.4 Technical data 8

4 Transport and storage 94.1 Scope of delivery 94.2 Packaging 94.3 Transport 94.4 Storage 9

5 Installation 105.1 Preparations 105.2 Installation and initial operation 105.3 Installing the electrical connections 11

6 Operation 126.1 Adjustable parameters 12

6.1.1 P (Pressure) 126.1.2 t (time / running time, cartridge

emptying times) 126.1.3 C (cycle / number of cycles,

strokes per lubrication cycle) 126.1.4 Pu (pulse mode) 136.1.5 U (cartridge size) 136.1.6 E (Error / inversion of

output signals) 136.1.7 L (empty signal) 136.1.8 F (feedback signal /

motor running check) 136.2 Selection of the parameters t and C. 146.3 Menu structure 156.4 Switching the lubricator on/off 16

6.5 Changing parameters in the standard menu (Pro) 176.6 Triggering a single lubrication sequence 186.7 Triggering the filling function (venting/filling) 196.8 Changing parameters in the Expert menu 206.9 Replace the cartridge 226.10 Replacing the battery 22

7 Messages and Errors 237.1 Pin assignment – time control 23

7.1.1 Overview of ouput signals (PIN4) – Time control 23

7.1.2 Standby – Time control 248 Pulse control 24

8.1 Control signals (PIN 2) 248.1.1 Overview of control signals 248.1.2 2sec signal (single pump stroke) 258.1.3 3sec signal (two pump strokes) 268.1.4 4sec signal (C pump strokes) 278.1.5 6sec / 12 sec signal

(filling/venting procedure) 288.1.6 10sec signal (acknowledge error

message) 298.2 Output signals (PIN 4) - Pulse control 30

8.2.1 Overview of output signals 308.2.2 Error E1 (empty) 308.2.3 Error E2 (no cartridge) 318.2.4 Transition of error E1 to E2 318.2.5 Error E3 (Low voltage) 328.2.6 Error E7 (Excess pressure) 32

9 Maintenance 339.1 Maintenance tasks 33

9.1.1 Visual inspection 339.1.2 Cleaning 33

9.2 Start up after maintenance 339.3 Maintenance schedule 349.4 Notes on the lubricant used 349.5 Disposal 34

10 Appendix 3510.1 Tightening torques for common thread sizes in general mechanical engineering 3510.2 Declaration of conformity 36

Lubricator Operating manual

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1 About this manual This manual contains the information required to be able to safely use the LUC+125 (FlexxPump 125), referred to from now on as the lubricator. Details contained in possibly added supplementary pages (e.g. for special applications) do apply. Contradictory details in this manual are thus rendered invalid. In case of questions regarding special applications, please contact WITTENSTEIN alpha GmbH. The user must ensure that this manual has been read and understood by all persons who are entrusted with the installation, operation or maintenance of the lubricator. Store the manual within reach of the lubricator. Inform your colleagues who work near the machine about the safety instructions so that nobody is injured. The original version of this manual was written in German. All other language versions are translations of this manual.

1.1 Signal words The following signal words are used to draw your attention to hazards, prohibitions and important infor-mation:

DANGERThis signal word indicates a directly impending hazard that will result in seri-ous injuries or even death.

WARNINGThis signal word indicates a possibly impending hazard which may result in serious injuries or even death.

CAUTIONThis signal word indicates a possibly impending hazard which may result in minor to serious injuries.

NOTEThis signal word indicates a possibly impending hazard which may result in damage to property.

EA note without a signal word indicates application hints or particularly im-portant information for the handling of the lubricator.


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1.2 Safety symbols The following safety symbols are used to draw your attention to hazards, prohibitions and important information:

General danger Electric voltage Flammable substances

1.3 Layout of the safety instructions Safety instructions in this manual are laid out according to the following pattern:

CAUTIONExplanatory text indicates the consequences of disregarding the note.• Instruction text directly indicates what needs to be done.

1.4 Information symbols The following information symbols are used: • requests you to take action indicates the consequences of an action provides you with additional information on the action


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2 Safety It is imperative that all persons who work with the lubricator follow this manual, in particular the safety instructions, as well as the rules and regulations applicable to the place of use. In addition to the safety instructions shown in this manual, the generally applicable legal and other rules and regulations for the prevention of accidents (e.g. personal protective equipment) and the protection of the environment must be obeyed.

2.1 EC/EU directive Within the scope of the EC/EU directive, initial operation is forbidden until such time as it has been determined that the machine into which this lubricator is installed conforms to the requirements of this directive. An EC/EU declaration of conformity for this lubricator can be found in the appendix (see section „10.2 Declaration of conformity”).

2.2 Hazards In order to avoid hazards for the user or damage to the machine, the lubricator may be used only for its intended use (see section „2.4 Intended use“) and only if it is in perfect working order. Before commencing work, read the general safety instructions (see section „2.7 General safety instructions“).

2.3 Personnel Only qualified personnel who have read and understood this manual may work on the lubricator.

2.4 Intended use Adhere to the following points in order to use the lubricator as it was intended:• The lubricator is approved only for industrial use.• The lubricator may be used only in accordance with the technical data (see section „3.4 Technical data“).• Unauthorized structural modifications to the lubricator are not permitted.• Read the operating manual and act accordingly.• During the operation of the lubricator a visual inspection of both the lubricator and the lubrication point is to be carried out regularly. Any abnormalities are to be rectified immediately!• Cartridge refill is not permitted.• Use only lubricants that have been approved by the manufacturer.• Obey the regulations for occupational health and safety and the prevention of accidents.• Work with and on the lubricator only with the appropriate authorization, see section „2.3 Personnel“.• All other types of use or the disregard of any of these points are regarded as inappropriate. In this case no liability can be accepted and/or warranties given.

2.5 Reasonably foreseeable misuse Any use that extends beyond the maximum permitted technical data is regarded as inappropriate and is therefore forbidden.


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2.6 Warranty and liability Warranty and liability claims in the case of personal injuries or damage to property are excluded in the case of

- disregarding the instructions for transport and storage- unintended use (misuse)- maintenance or repair work carried out improperly or not at all- improper assembly/disassembly or improper operation (e.g. test run without secure

attachment)- operation of the lubricator with defective protective devices and fixtures- operation of the lubricator without lubricant- operation of the lubricator with non-approved lubricant- operation of the lubricator when it is very dirty- changes or modifications made without the written consent of

WITTENSTEIN alpha GmbH

2.7 General safety instructions

DANGERFaulty electrical connections or unapproved conducting components will result in serious injuries or even death.• Have all electrical connection work done by qualified personnel only.• Replace damaged cables or plug connectors immediately.

NOTELoose or overloaded screw connections can cause damage to the lubricator.• Mount and check all screw connections for which tightening torques are specified using a calibrated torque wrench.

WARNINGLubricants are combustible.• Do not use water jets to extinguish fires.• Suitable extinguishing agents are powder, foam, water mist and carbon dioxide.• Observe the safety instructions issued by the lubricant manufacturer (see section “9.4 Notes on the lubricant used”).

CAUTIONSolvents and lubricants can lead to skin irritations.• Avoid direct skin contact.

Solvents and lubricants can pollute soil and bodies of water.• Use and dispose of cleaning solvents and lubricants properly.


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3 Functional description The lubricator has a double-piston pump. The two pistons run in opposite directions, where one piston draws in the lubricant while the other pumps the quantity drawn in during the previous stroke to the outlet. 0.15 cm³ of lubricant is pumped per stroke or dosing sequence. The lubricator can be controlled via an external controller (PLC) - pulse controlled. Alternatively the time and frequency of the lubrication and the quantity of lubricant per lubrication sequence can be defined via the parameters t and C - time controlled. Operating condition and error messages are displayed on the LCD. The conditions and errors can additionally be read out and interpreted on the external controller.

SET

6

1

2

3

4

5

7

89

10

1 LCD2 Action field3 Lubricant supply4 Type plate5 M5 thread for rear-side mounting

6 Sensor pin for cartridge7 M12x1 connector8 Magnetic pin9 Hydraulic connection / outlet10 M5 thread for mounting from underneath


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3.1 Type plate

The type plates of the lubricator are attached to the pump and cartridge.

3.2 Marking

The lubricator is clearly identified by an additional type plate with the serial number. The CE mark is applied visibly to the type plate.

Manufacturer

DLS Schmiersysteme GmbHGewerbering 5D-82140 OlchingPhone: +49-(0)8142-65069-0Fax: +49-(0)8142-65069-29e-mail: [email protected]

3.3 Ordering code

L U C+ 1 2 5 - -0 5 1 1 0 5

TypeLUC+ = electromechanical lubricator

Size(Volume of lubricant)125 = 125 cm³250 = 250 cm³

Lubricant05 = WITTENSTEIN alpha G1106 = WITTENSTEIN alpha G1207 = WITTENSTEIN alpha G13

Number of outlets1 = 1 pump, 1 outlet

Principle of operation1 = 24 V, pulse controlled2 = 24 V, time controlled3 = battery version, time controlled4 = battery version, time controlled, pressure relieved 12 bar

Tube length00 = no tube02 = 2000 mm05 = 5000 mm


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3.4 Technical data HousingDimensions with 125 cm³ cartridge(W x H x D)

83 x 152 x 83 mm

Dimensions with 250 cm³ cartridge(W x H x D)

83 x 190 x 83 mm

Weight (without lubricant) approx. 350 gMounting possibilities Rear side 2 x M5

Underside 1 x M5 and/or G1/4"Torque M5 3 NmMounting position arbitrary, preferably verticalPermissible operating temperature -20 °C to +70 °CMaterial PA 6.6 GF 30 / POM

LubricantsCartridge volume 125 cm³ / 250 cm³

Lubricant type Grease up to NLGI Class 3, solid contents possible Hydraulic data 24V Version Battery VersionNumber of outlets 1 1Thread of outlet G1/4" and M6 G1/4" and M6Number of lubrication points up to 4 in conjunction with

splitterup to 14 in conjunction with progressive distributor

up to 4 in conjunction with splitterup to 10 in conjunctionwith progressive distributor

Hydraulic connection Direct or via additional tube connection to PA tube

Direct or via additional tube connection to PA tube

Max. pressure 12 or 50 bar (adjustable) 12 or 35 bar (adjustable)Dosing volume/stroke 0.15 cm³ 0.15 cm³

Number of pump strokes per cartridge

approx. 830 (with 125 cm³) / approx. 1660 (with 250 cm³)

apprx. 830 (with 125 cm³)

Electrical data 24V Version Battery VersionDisplay LCD LCD

Operating voltage 24 V DC (external) +/- 5 % 4.5 V

Current input Imax < 300 mAstandby current < 25 mA

-

Fuse 750 mA, slow-blow -

Connecting plug M12x1, 4-pole M12x1, 4-pole

Protection class IP 54 IP54


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4 Transport and storage

4.1 Scope of delivery

• Check the completeness of the delivery against the bill of delivery. Missing parts or damage must be reported immediately in writing to the freight forwarder, the

insurance company or WITTENSTEIN alpha GmbH.

4.2 Packaging The lubricator is delivered packed in plastic foil and boxes.• Dispose of the packaging material at the disposal points provided for the purpose. Observe the applicable national regulations for disposal.

4.3 Transport

NOTEHard knocks such as falling down or being set down too hard can damage the lubricator.• Use only lifting and load attachment devices with a sufficient load capacity.• The permissible lifting weight of a lifting device may not be exceeded.• Set the lubricator down slowly.

WARNINGSuspended loads can fall down and cause serious injuries or even death.• Never walk or remain under suspended loads.

4.4 Storage Store the lubricator in the original packaging in a horizontal position and a dry environment at a tempe-rature of 0 °C to + 30 °C. Store the lubricator for a maximum of 2 years. We recommend the “first in – first out” principle for the storage logistics.


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5 Installation

• Before commencing work, read the general safety instructions (see section 2.7 “General safety instructions”).

5.1 Preparations

NOTECompressed air can damage the seals of the lubricator.• Do not use compressed air to clean the lubricator.

5.2 Installation and initial operation

The lubricator is delivered vented with a screwed-on cartridge and mounting bracket mounted.

Optional:• Unscrew the cap of the cartridge.• Screw the cartridge onto the lubricator.• Mount the lubricator in the desired position (see section „3.4 Technical data“ for the mounting specifications).

Mount the supplied tube connector.Max. tightening torque: 2 Nm.


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• Observe the instructions for safety and use of the thread locking compound used

Apply a thread-locking compound (e.g. Loctite® 243) to the fastening screws.

• Fasten the lubricator with the pre-mounted hold-ing bracket in the intended position. Fine adjustment of the installation height is possible by means of the slotted holes. The prescribed screw sizes and tighten-ing torques can be found in Table 2.

Through-holes in the mounting bracket

Type/size Hole spacing[mm]

Number x diameter[ ] x [mm]

For screw size / property class

Tightening torque[Nm]

LUC+12595 2 x 6.6 M6 / 8.8 9.0

LUC+250

Table 2: Through-holes in the mounting bracket

5.3 Installing the electrical connections

DANGERIf touched, live components will lead to electric shocks which can cause serious injuries or even death.• Before carrying out electrical installation work, observe the five safety rules of electrical engineering:

– Switch off. – Secure against unintentional restart of power. – Check that no voltage is present. – Ground and short circuit. – Cover adjacent and electrically live parts.

• Check whether the protective caps are fitted to the plugs. Check the plugs for damage and dirt if protective caps are missing.

DANGERIn the presence of moisture electrical work can lead to electric shocks which can cause serious injuries or even death.• Carry out the electrical assembly only in dry rooms.


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6 Operation Depending on the mode (time or pulse mode), the lubricator is operated with the magnetic pin provided or via an external controller. However, the individual control parameters can subsequently be changed.

6.1 Adjustable parameters

Para-meter

DesignationPermissible values

Factory setting time control

Factory setting pulse control

Change to

P Maximum pressure [bar] 12 / 50 50 50 Expert menut Cartridge emptying time

[months]1 ... 24* ... 36 6 -

Standard menu and Expert menu

C Number of cycles [0.15 cm³/stroke]

1 / 2 / ... / 10 2 1

Pu Pulse mode 0 / 1 0 1U Cartridge size [x 10 cm³] 12 / 25 12 12

Expert menuE Inversion of output signals 0 / 1 1 0L Empty signal 0 / 1 / 2 1 2F Feedback signal 0 / 1 0 1* only battery version

6.1.1 P (Pressure)

The parameter P indicates the maximum counter pressure. It can be set to 12 bar, 35 bar (only battery version) or 50 bar. The maximum pressure of the system may need to be reduced depending on the system in use and the lines connected (e.g. tubes). If the preset maximum pressure is exceeded, the lubricator goes into the fault status and stops the current lubrication cycle. A message is displayed on the LCD and sent to an external controller.No further pumping sequence takes place until the message has been acknowledged.

6.1.2 t (time / running time, cartridge emptying times)

The parameter t can only be adjusted if the parameter Pu0 is set. With the parameter Pu1 the emptying time is controlled externally by a controller.The parameter t indicates the time in which the cartridge should be emptied. The emptying time can be set from 1 to 36 months (battery version max. 24 months). For further information, see „6.2 Selection of the parameters t and C.

6.1.3 C (cycle / number of cycles, strokes per lubrication cycle)

The parameter C indicates how many dosing strokes take place per lubrication cycle, or how much lubricant is supplied. 1 to 10 dosing strokes can be set. With a value of C4, four dosing strokes of 0.15 cm³ each take place.


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6.1.4 Pu (pulse mode)

The parameter Pu indicates the mode in which the lubricator is operating. With Pu1 the dosing is con-trolled by an external controller. With Pu0 the dosing is controlled by the parameter t.

6.1.5 U (cartridge size)

The parameter U indicates which cartridge size is being used. U12 stands for cartridge size 125 cm³, U25 for cartridge size 250 cm³.

6.1.6 E (Error / inversion of output signals)

The parameter E indicates whether the signal images to an external controller for empty state, error message and feedback (motor running check) are generated inversely. For further information, see section „7.1.1 Overview of ouput signals (PIN4) – Time control“, „8.2 Output signals (PIN 4) - Pulse control“.

6.1.7 L (empty signal)

The parameter L indicates how the signal image for the empty signal is sent to an external controller. This parameter is dependent on parameter E. For the setting E0, only the values L0 (low-level signal) and L2 (rectangular signal) are possible for L. For the setting E1, only the values L1 (high-level signal) and L2 (rectangular signal) are possible for L.

6.1.8 F (feedback signal / motor running check)

The parameter F indicates whether a signal is sent to an external controller during a pumping sequence (motor running). This parameter is dependent on parameter E. For the setting E0 the lubricator sends a low-level signal to an external controller during the pumping stroke; the pumping stroke cannot be recognized in the controller. For the setting E1 the lubricator sends a high-level signal to an external controller during the pumping stroke; the pumping stroke is registered.


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6.2 Selection of the parameters t and C.

NOTEThe emptying time t can only be set on the lubricator when it is not controlled by an external controller (Pu0).

Emptying time t for 125 cm³ cartridge (U12)t (months) 1 3 6 10 12 15 20 24 30 36

Lubricating quantity per month [cm³] 125 41.6 20.8 12.5 10.4 8.3 6.3 5.2 4.2 3.5

Emptying time t for 250 cm³ cartridge (U25)t (months) 1 3 6 10 12 15 20 24 30 36Lubricating quantity per month [cm³] 250 83.3 41.6 25 20.8 16.7 12.5 10.4 8.3 6.9

Values for t are examples; values from 1 to 36 (24 V version) / 1- 24 (battery version) can be set. Number of cycles C, strokes per cycleC 1 2 3 4 5 6 7 8 9 10Lubricating quantity per cycle [cm³] 0.15 0.30 0.45 0.60 0.75 0.90 1.05 1.20 1.35 1.50

The emptying time t specifies the period over which the entire quantity of lubricant is supplied per car-tridge. Correspondingly, it also defines how much lubricant is supplied per month. The number of cycles C indicates how many strokes take place per lubrication and thus how much lubricant is supplied per lubrication. The time between two lubrications (dwell time) can be determined with the following equation: Tdwell = t x 720 h x C / H With t in hours and H as the total number of strokes per cartridge (830 with a 125 cm³ cartridge), the dwell time for a lubricating quantity of 0.60 cm³ (C4) over six months is calculated below: Tdwell = 6 x 720 h x 4 / 830 = 20.9 h The result of the calculation is a lubrication cycle of 21 hours. 0.60 cm³ of lubricant are supplied every 21 hours over a period of six months.


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6.3 Menu structure The following illustration shows the complete menu structure of the lubricator.

MAX1

MAX1 MAX2 MAX1 MAX2 MAX1

3x 7x

Action by user, LED flashes red once

Lubricator is ready for operation, but is not switched on

Sequence / reaction in menu Lubricator is in operation

LED on LCD flashes greenLubricator is waiting for a signal from the external controller

LED on LCD flashes red Carry out a single dosing stroke

LCD display flashes twice Programming

Firmware information Expert menu

Programming (Standard menu)

Expert menu


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6.4 Switching the lubricator on/off

3x

Switching on1. Hold the magnetic pin against the action field. The LED flashes three times red.2. Remove the magnetic pin when the display indicates ON.3. The firmware information and the settings for Emptying time (t) and Number of cycles (C) are displayed. On flashes twice on the LCD The green LED flashes; the lubricator is in operation. The lubricator discharges lubricant in accordance with the presets for t and C. If the LCD displays PAU, the lubricator is not receiving a control signal from an external controller. Switching off1. Hold the magnetic pin against the action field. The LED flashes red and run, On and OFF are displayed in succession on the LCD.2. Remove the magnetic pin when the display indicates OFF. OFF flashes twice on the LCD. The lubricator is switched off.


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6.5 Changing parameters in the standard menu (Pro) The following parameters can be set in the standard menu:Pulse mode PuEmptying time tNumber of cycles C

A description of the individual parameters can be found in section “6.1 Adjustable parameters”.

NOTEThe emptying time t can only be set on the lubricator when it is not controlled by an external controller (Pu0 / time controlled).

Changing parametersaLubricator in operation (PAU / On)

1. Hold the magnetic pin against the action field. The LED flashes red and run, On, OFF, On and Pro are displayed in succession on the LCD.2. Remove the magnetic pin when the display indicates Pro. The display shows the parameters Pu, t and C in succession (depending on the lubricator type).3. When the parameter to be set is displayed, hold the magnetic pin against the action field. On the LCD the value for the parameter is incremented and starts again from the beginning after reaching the highest value.4. Remove the magnetic pin from the action field when the desired value is displayed. The set value flashes twice. The next parameter is displayed on the LCD. After the last parameter the lubricator returns to operation again automatically.


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6.6 Triggering a single lubrication sequence You can trigger a single lubrication sequence at any time during operation with the lubricator.

MAX1

aLubricator in operation (PAU / On)

1. Hold the magnetic pin against the action field. The LED flashes red.

2. Remove the magnetic pin when the display indicates run. The lubricator performs a single lubrication sequence. The LCD displays the approximate counter pressure and the pumping piston. On completion of the lubrication sequence the lubricator returns automatically to operation.


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6.7 Triggering the filling function (venting/filling)

The lubricator is delivered vented with a screwed-on cartridge and mounting bracket mounted. You can trigger the filling function of the lubricator for venting or filling. The lubricator then automatically performs 40 pumping strokes with a total lubricating quantity of 6 cm³ of lubricant.You can abort the filling function again manually.

MAX1 MAX2 MAX1 MAX2 MAX1

aLubricator in operation (PAU / On)

1. Hold the magnetic pin against the action field. The LED flashes red and run, On, OFF, On, Pro, On, and FIL are displayed in succession on the LCD.2. Remove the magnetic pin when the display indicates FIL. The lubricator begins with the filling procedure. The LCD displays the approximate counter pressure and the pumping piston. On completion of the lubrication sequence the lubricator returns automatically to operation.

Aborting the filling procedure1. Hold the magnetic pin against the action field during the filling procedure. The LCD displays CLr.2. Remove the magnetic pin. The filling function is aborted. The lubricator goes automatically into operation.


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6.8 Changing parameters in the Expert menu

NOTEChanges made in the Expert menu can fundamentally affect the function of the lubricator. Change the parameters in the Expert menu only if you are aware of the effects..

The following parameters can be set in the Expert menu:• Pulse mode Pu• Emptying time t• Number of cycles C• Pressure P• Cartridge size U• Inversion of the output signals E• Empty signal L• Feedback / Motor running check F A description of the individual parameters can be found in section “6.1 Adjustable parameters”.

NOTEThe emptying time t can only be set on the lubricator when it is not controlled by an external controller (Pu0).


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3x 7x

Changing parametersaLubricator ready for operation, but is not switched on (OFF)

1. Hold the magnetic pin against the action field. The LED flashes red three times, then On is displayed on the LCD followed by OFF. The LED flashes red seven times and EP is displayed on the LCD.2. Remove the magnetic pin when the display indicates EP. The LCD displays the first editable parameter.3. Hold the magnetic pin against the action field to change the parameter. On the LCD the value for the parameter is incremented and starts again from the beginning after reaching the highest value.4. Remove the magnetic pin from the action field when the desired value is displayed. The set value flashes twice. The next parameter is displayed on the LCD. The current value flashes twice if the parameter is not changed. After the last parameter the lubricator returns to standby mode again automatically (OFF).


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6.9 Replace the cartridge

NOTEAn opened cartridge may not be screwed on again. Only full cartridges may be in-stalled because the counter is reset by removing a cartridge.

NOTEUse only original cartridges.

A cartridge can be replaced during the normal operation. If the cartridge is empty the LCD displays E1 and the LED flashes red. If a dosing sequence was interrupted it will be resumed automatically after screwing on a new cartridge.

1. Unscrew the empty cartridge and dispose of it properly. The display on the LCD changes from E1 to E2. The LED flashes red.2. Screw on a new full cartridge until the type plate is facing forwards. Any interrupted dosing sequence will be resumed. The LED flashes green.

6.10 Replacing the battery

If using the battery version, the battery must be replaced at the same time as the cartridge.

• Observe the safety instructions for the battery.

• Remove the battery.• Disconnect the plug.• Connect the plug to the new battery.• Insert the battery.• Dispose of the old battery in accordance with the applicable national regulations.


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7 Messages and ErrorsThe following messages may appear on the LCD of the lubricator.

LCD display Meaning TroubleshootingOFF The lubricator is connected and

switched offPAU The lubricator is connected and is

waiting for a signal from the controllerON The lubricator is in operation and

supplying lubricant according to the time or pulse specification

E1 Empty Replace the cartridgeE2 No cartridge present Screw on a cartridgeE3 Undervoltage Adjust the supply voltage.

Acknowledge the error message.E7 Excess pressure Check the lubrication points.

Check the setting of the parameter for pressure (P).

7.1 Pin assignment – time control

PIN 24V Version Battery Version

1

2

4

3

PIN 1 +24 V DC +24 V DC

PIN 2 unassigned Input ON / OFF

PIN 3 Ground / - (GND) Ground / - (GND)

PIN 4 Output signal Output signal

7.1.1 Overview of ouput signals (PIN4) – Time controlThe following descriptions apply to the factory setting of the parameter E (E1), L and F, see section „6.1.6 E (Error / inversion of output signals)“.

Anzeige LCD Bezeichnung Signal BeschreibungOFF Switched off low, continuous Lubricator switched offOn Ready for operation low, continuous Lubricator is ready for operationE1 Empty high, continuous Cartridge is emptyE2 No cartridge high, continuous No cartridge attachedE3 Undervoltage high, continuous Supply voltage is too lowE4 bis E6 not used - -E7 Excess pressure high, continuous Maximum permissible pressure has been

reached


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7.1.2 Standby – Time controlThe 24 V version can be switched off completely by switching off the supply voltage. The presettings are not getting lost.The battery version can be put into standby via a potential-free limit switch between PIN 2 and PIN 3. Maximum cable length is 5m.

8 Pulse controlM12x1 connector for external controller

1

2

4

3

1. PIN 1, +24 V DC2. PIN 2, control signals3. PIN 3, ground4. PIN 4, output signals The lubricator has a 4-pin plug connector for connection to the controller of a machine (for external control of the lubricator). This is located at the bottom of the housing.

8.1 Control signals (PIN 2)

This section describes the signals for controlling the lubricator from an external controller. The values and settings refer to the factory settings of the lubricator, see section “6.1 Adjustable parameters”.The lubricator is controlled exclusively by means of high-level signals on PIN 2.

8.1.1 Overview of control signalsThe lubricator provides the following predefined control signals (input signals).

Signal length Designation Function Description2sec high 2sec signal 1 pump stroke Execution of a single lubricating sequence3sec high 3sec signal 2 pump strokes Execution of two successive lubricating se-

quences4sec high 4sec signal C pump strokes Lubricating sequences according to the set-

ting of parameter C6sec high 6sec signal 40 pump strokes Venting or filling function10sec high 10sec signal Error

acknowledge-ment

Acknowledgement of error messages

12sec high 12sec signal 40 pump strokes Venting or filling function


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8.1.2 2sec signal (single pump stroke)

The 2sec signal triggers a single pump stroke and thus a lubrication sequence. The signal can be repeated after a dwell time.

U

0 V

24 V

t2 s

Tp

U

0 V

24 V

t> 3 s > 3 s

ML

PIN 2

PIN 4

Tp: Dwell timeML: Motor running time Description• The lubricator transmits a permanent output signal (high level) on PIN 4 to signal its readiness for operation to the controller. This signal must be present without interruption for at least 4 seconds before a control signal can be transmitted to the lubricator.• The 2sec 24 V signal (1.9 s ... 2.1 s) can then be transmitted to the lubricator.• After the signal drops to 0 V, the pump motor starts to run and the lubricator pumps lubricant. The motor running time (ML) depends on the lubricant and the counter pressure (7 s ... 17 s).

The lubricator can process the next signal at the earliest 3 seconds after the completion of the motor run (dwell time Tp at least 22 seconds).


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8.1.3 3sec signal (two pump strokes)

The 3sec signal triggers two consecutive pump strokes and thus two lubrication sequences. The signal can be repeated after a dwell time.

U

0 V

24 V

t3 s

Tp

U

0 V

24 V

t> 3 s > 3 s

ML ML

PIN 2

PIN 4

P

Tp: Dwell timeML: Motor running timeP: Pause between motor runs Description• The lubricator transmits a permanent output signal (high level) on PIN 4 to signal its readiness for operation to the controller. This signal must be present without interruption for at least 3 seconds before a control signal can be transmitted to the lubricator.• The 3sec 24 V signal (2.9 s ... 3.1 s) can then be transmitted to the lubricator.• After the signal drops to 0 V, the first motor run of the pump starts and the lubricator pumps lubricant. The motor running time (ML) depends on the lubricant and the counter pressure (7 s ... 17 s).• After the completion of the first pumping sequence the lubricator transmits a pause signal (P = 0.5 s).

The lubricator can process the next signal at the earliest 3 seconds after the completion of the second motor run (dwell time Tp at least 38 seconds).


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8.1.4 4sec signal (C pump strokes)

The 4sec signal triggers one or more pump strokes and thus starts lubrication sequences in accordance with the setting of the parameter C. The signal can be repeated after a dwell time.

U

0 V

24 V

t4 s

U

0 V

24 V

t> 3 s

ML

PIN 2

PIN 4

ML ML ... Cx

P P P

Tp: Dwell timeML: Motor running timeP: Pause between motor runsCx: Number of cycles Description• The lubricator transmits a permanent output signal (high level) on PIN 4 to signal its readiness for operation to the controller. This signal must be present without interruption for at least 4 seconds before a control signal can be transmitted to the lubricator.• The 4sec 24 V signal (3.9 s ... 4.1 s) can then be transmitted to the lubricator.• After the signal drops to 0 V, the first motor run of the pump starts and the lubricator pumps lubricant. The motor running time (ML) depends on the lubricant and the counter pressure (7 s ... 17 s).• After the completion of the first pumping sequence the lubricator transmits a pause signal (P = 0.5 s). The second motor run follows thereafter. The sequence is repeated C times.

The lubricator can process the next signal at the earliest 3 seconds after the completion of the Cth motor run (dwell time Tp at least (C x 17.5) + 4 s).


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8.1.5 6sec / 12 sec signal (filling/venting procedure)

The 6sec and 12 sec signals are identical and initiate the filling or venting procedure respectively.The signal can be repeated after a dwell time.The 6sec signal is described below.

U

0 V

24 V

t6 s

U

0 V

24 V

t> 3 s

ML

PIN 2

PIN 4

ML ML ... 40x

P P P

Tp: Dwell timeML: Motor running timeP: Pause between motor runs Description• The lubricator transmits a permanent output signal (high level) on PIN 4 to signal its readiness for operation to the controller. This signal must be present without interruption for at least 4 seconds before a control signal can be transmitted to the lubricator.• The 4sec 24 V signal (6.9 s ... 12.1 s) can then be transmitted to the lubricator.• After the signal drops to 0 V, the first motor run of the pump starts and the lubricator pumps lubricant. The motor running time (ML) depends on the lubricant and the counter pressure (7 s ... 17 s).• After the completion of the first pumping sequence the lubricator transmits a pause signal (P = 0.5 s). The second motor run follows thereafter. The sequence is repeated 40 times.

The lubricator can process the next signal at the earliest 3 seconds after the completion of the last motor run (dwell time Tp at least (40 x 17.5) + 6 s).


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8.1.6 10sec signal (acknowledge error message)

The 10sec signal is to acknowledge error messages.

U

0 V

24 V

t10 s

U

0 V

24 V

t> 3 s

PIN 2

PIN 4

Description:• If an error occurs on the lubricator, it transmits a low-level signal to the controller on PIN 4. This signal must be present without interruption for at least 4 seconds before the error message can be acknowledged.• The 10sec 24 V signal (9.9 s ... 10.1 s) can then be transmitted to the lubricator.• After the signal drops to 0 V the error is cleared and the LCD displays CLr.

If an error had occurred during the execution of a control signal, this sequence will be resumed after rectification of the error.


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8.2 Output signals (PIN 4) - Pulse control This section describes the signals which the lubricator transmits to an external controller. The following descriptions apply to the factory setting of the parameter E (E0), see section “6.1.6 E (Error / inversion of output signals)”.

8.2.1 Overview of output signals

The lubricator transmits the following predefined output signals to an external controller.

LCD display Designation Signal Description

OFF Switched off low, continuous Lubricator switched off

On Ready for operation high, continuous Lubricator is ready for operation

E1 Empty 0.5 Hz, rectangular Cartridge is empty

E2 No cartridge low, continuous No cartridge attached

E3 Undervoltage low, continuous Supply voltage is too low

E4 to E6 not used

E7 Excess pressure low, continuous Maximum permissible pressure has been reached

8.2.2 Error E1 (empty)

Error E1 signals that cartridge is empty.

U

0 V

24 V

t> 3 s

1 s

PIN 4

Description:• The circuitry in the lubricator counts the dosing sequences according to the cartridge in use. 830 dosing sequences are possible with a 125-cm³ cartridge, 1660 with a 250-cm³ cartridge.• Error E1 (empty signal) can only occur after a dosing sequence; any subsequent dosing will be not started.• The error cannot be acknowledged; after removal of the empty cartridge error E1 becomes the error E2.


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8.2.3 Error E2 (no cartridge)

Error E2 signals that no cartridge is screwed onto the lubricator.

U

0 V

24 V

t> 3 s

PIN 4

Description:• The lubricator’s sensor pin detects whether a cartridge is screwed onto the lubricator. The amount of lubrication in the cartridge is not detected.• Error E2 interrupts running dosing sequences and prevents further control signals.• Error E2 is displayed until a cartridge is screwed on; the error need not be acknowledged.

NOTEAn opened cartridge may not be screwed on again. Only full cartridges may be installed because the counter is reset by removing a cartridge

8.2.4 Transition of error E1 to E2

The following diagram shows the signal curve when replacing a cartridge.

U

0 V

24 V

t

PIN 4

E1 E2Z1 Z2

Z1: Removal of the empty cartridgeZ2: Installing the new cartridge

Description:• Error E1 occurred after a dosing sequence; the lubricator transmits the empty signal (E1).• Z1 marks the removal of the empty cartridge; the lubricator transmits the signal for error E2 (no cartridge).• Z2 marks the installation of a new cartridge.• If a running dosing sequence is interrupted by the error E1, it will be resumed after installing the new cartridge.


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8.2.5 Error E3 (Low voltage)

Error E3 signals that the lubricator supply voltage is too low.

U

0 V

24 V

t> 3 s

PIN 4

Description:• If the supply voltage is too low the lubricator transmits a continuous low-level signal and no further control signals are processed.• The error message must be acknowledged with the 10sec signal after rectification of the error.

8.2.6 Error E7 (Excess pressure)

Error E7 signals that the maximum pressure is exceeded during a dosing sequence.

U

0 V

24 V

t> 3 s

PIN 4

Description:• Upon reaching the preset maximum pressure the lubricator transmits a continuous low-level signal and no further control signals are processed.• The error message must be acknowledged with the 10sec signal after rectification of the error.


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9 Maintenance

• Before commencing work, read the general safety instructions (see section “2.7 General safety instructions”).

9.1 Maintenance tasks

9.1.1 Visual inspection

NOTEInsufficient lubrication will damage the toothing.• Always ensure sufficient lubrication and replace the lubricant cartridge in a timely manner.

• Check the entire lubrication system by means of a thorough visual inspection for external damage such as loose or defective tubes and worn or dirty (clogged) lubricating pinions.• Replace damaged parts immediately in order to ensure constant lubrication.• The service life of the lubricating pinion depends on the environmental conditions.• Check the fill level in the lubricator.

9.1.2 Cleaning

NOTECompressed air can damage the seals of the lubricator.• Do not use compressed air to clean the lubricator.

9.2 Start up after maintenance

• Clean the outside of the lubricator.• Attach all safety devices.• Carry out a test run before releasing the lubricator for operation again.


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9.3 Maintenance schedule

Maintenance tasks During start-upAfter 500 operating

hours or three monthsAnnually

Visual inspection and cleaning

x x x

Check the tightening torques

x x x

Table 3: Maintenance schedule

9.4 Notes on the lubricant used

The lubricant may differ depending on the application. The lubricant used is specified on the type plate of the lubricator.

Further information on the lubricants can be obtained directly from WITTENSTEIN alpha.

9.5 Disposal

• Observe the safety data sheets and disposal instructions when disposing of the lubricator and dispose of it along with the empty cartridges and batteries in accordance with the applicable national regulations.

NOTEEmpty cartridges cannot be refilled. Do not charge the batteries.


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10 Appendix

10.1 Tightening torques for common thread sizes in general mechanical engineering The specified tightening torques for set screws and nuts are calculated values and are based on the following prerequisites: – Calculation according to VDI 2230 (February 2003 edition) – Coefficient of friction for thread and contact surfaces μ = 0.10 – Utilisation of the elastic limit 90%

Tightening torque [Nm] for threads

Property class

Screw / nut

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24

8.8 / 8 1.15 2.64 5.24 8.99 21.7 42.7 73.5 118 180 258 363 493 625

10.9 / 10 1.68 3.88 7.69 13.2 31.9 62.7 108 173 265 368 516 702 890

12.9 / 12 1.97 4.55 9.00 15.4 37.3 73.4 126 203 310 431 604 821 1042

Table 4: Tightening torques


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10.2 Declaration of conformity


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WITTENSTEIN alpha GmbHWalter-Wittenstein-Straße 197999 Igersheim

WITTENSTEIN – eins sein mit der Zukunft

www.wittenstein.de

Lubricator LUC 125

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