ИТЦ ТЕХСЕРВИС - Quicklub · 2017-10-01 · 2.1A-30005-A04 Page 4 of 44 LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49

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Owner ManualTechnical Description

2.1A-30005-A04

LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49 (6227) 33-259

Quicklub® Pump Model 203 with Power Supply

for 110-230 VAC and Printed Circuit Board M08-M23

6337b04

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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.

© 2004 by LINCOLN GmbH & Co. KG Postfach 1263 D-69183 Walldorf

Phone: +49 (6227) 33-0 Fax: +49 (6227) 33-259

Fields of Application of Quicklub Progressive Centralized Lubrication Pumps

Industry - Machines Pump Type

Pump: Reservoir: Low Level Control: Control:

Quicklub 203 with integrated power supply unit 2 L -2XL2), 2XLBO1), 2YLBO3) 4 L -4XLBO1), 4YLBO3) 8 L - 8XLBO1), 8YLBO3) 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) with control unit M08 to M234)

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: Technical Description 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

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Keep this user information always at hand at the place of work of the pump!

Table of Contents

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 ......................................................... 10 Pump Elements with fixed Lubrication output .................. 10 Pump element B7 with bypass check valve................ 10 Check valve ............................................................... 11 Arrangement of the pump elements ........................... 11 Pump Elements with adjustable Lubrication output ......... 11 Setting of adjustable pump elements ......................... 12 Retrofit adjustment of max. lubricant output ............... 12 Retrofit adjustment of min. lubricant output ................ 13 Pressure relief valve ........................................................ 13 without grease return ................................................. 13 with grease return ...................................................... 13 Return Line Connection ................................................... 14 Low Level Control (Option) - for Oil: Float magnetic switch ........................................ 14 Contact protection measures ........................................... 15 - for grease ...................................................................... 15 Reservoir filled ........................................................... 15 Reservoir empty ......................................................... 15

Page

Printed Circuit Boards M08-M23 ................................... 17 Fields of Application ......................................................... 17 Installation position of the printed circuit board ................ 17 Advantages ...................................................................... 17 Start up ............................................................................. 17 Applications ...................................................................... 18 Control Unit Mode of Operation ........................................................... 19 Pause time ................................................................. 19 Operating time ............................................................ 19 Monitoring time ........................................................... 20 Time storage .............................................................. 20 Time Setting ..................................................................... 21 Setting Pause time ..................................................... 21 Factory Setting ........................................................... 21 Functional Check and Fault Indication ............................. 22 Functional check when switching on .......................... 22

Operational test / To trigger an additional lubrication cycle .................................... 22

Signal Output .............................................................. 23 Acknowledging receipt of a malfunction ..................... 23 Function of the pushbutton for additional lubrication cycles ................................... 24 LED function (M08-M23) ............................................ 24 LED function (M16-M23) ............................................ 24 Fault Indication ........................................................... 24 - M08-M15 .................................................................. 24 - M16-M23 .................................................................. 25 To Remedy to a Fault ...................................................... 25 Maintenance, Repair and Tests .................................... 27 Maintenance .................................................................... 27 Pump Filling ................................................................27 Repair .............................................................................. 28 Pump .......................................................................... 28 Replace pump element .............................................. 28 Printed Circuit Boards ................................................. 28 Tests ................................................................................ 29 Operational Test / To trigger an Additional Lubrication Cycle .................................. 29 To check the pressure relief valve .............................. 29 Functional Check of the p.c.b. .................................... 29 Troubleshooting ............................................................. 30 Technical Data ................................................................ 32 Electrical Data .................................................................. 33 Connection Diagram ........................................................ 34 Combination of the jumper positions - Survey .................. 35 Terminals of the p.c.b. ..................................................... 36 Attaching Bores ................................................................ 36 Dimensions ...................................................................... 37 Declaration of the Manufacturer ................................... 41 Lubricants ....................................................................... 42

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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:

1013A94

4273a00

6001a02

- ATTENTION - CAUTION - WARNING

- ATTENTION - CAUTION - WARNING

- NOTE - IMPORTANT

The signal words give the seriousness of danger if the follow-ing text is not observed: ATTENTION refers to faults or damages on

machines. CAUTION refers to bad damages and possi-

ble injuries. WARNING refers to possible dangerous inju-

ries. NOTE refers to improvements in handling

of systems. IMPORTANT refers to considerable disadvan-

tages in handling of systems. Example:

1013A94

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.

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 responsi-ble for the following: 1. The pump / system shall be operated only for the in-

tended 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 accor-dance 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 re-sponsibility. Lincoln GmbH & Co. KG will gladly assist you with any questions pertaining to the installation.

Environmental Protection

Waste (e.g. used oil, detergents, lubricants) must be dis-posed of in accordance with relevant environmental regula-tions.

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.

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Safety Instructions

Appropriate Use

� Use the 203 pump only for dispensing lubricants in cen-tralized lubrication systems. The pump is designed for in-termittent 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.

6001a02

NOTE

If personal injury or material damage occurs as a result of inappropriate opera-tion, 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 Cata-logue) 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.

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Safety Instructions, continuation

Operation, Repair and Maintenance

4273a00

CAUTION!

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 0160. Install a protective and lock out device for isolating and disconnecting the pump 203. Before beginning the installation work, disconnect the elec-trical supply.

4273a00

WARNING!

Failure to observe the safety instruc-tions, e. g. touching electrically charged parts when the pump is opened, or improper handling of the pump 203 may cause serious injury or death. If the values specified in the Technical Data are exceeded, the de-vice may overheat. It may damage the pump 203 and thus impair the electric safety.

� Repairs should only be performed by authorized person-nel 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

CAUTION!

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!

1013A94

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 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 (ap-proximately every 2 days) should be made to ensure that lubricant is being dispensed from all lubricant points.

6001a02

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 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 condi-tionally 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 compo-nents.

� caused by the use of unapproved parts.

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Pump Types

1173a95

Fig. 1 The different types of pump 203

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 sim-ply 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 Technical Description) 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-V132) for alternate current 120, 230 VAC � with metering device monitoring (microprocessor control),

M08-M23 � with metering device monitoring (microprocessor control)

M08-M232) 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 K6 - 24 - 2A1.01 - V10 Also refer to the designation code on page 8.

- Refer to the designation on the pump nameplate. Example: P203 - 2XLBO - 1K6 – AC - 3A6.15 - M08 Also refer to the designation code on page 8.

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Identification Code – AC Pump Models P203 with Control p.c.b. M08-M23

Examples of model designations P203 - 2 X L - 1 K6 - AC - 3A 6. 15 - M08

P203 - 4 X L BO - 1 KR - AC - 3A 6. 15 - M10

P203 - 2 X L - 2 K5 - AC - 3A 6. 15 - M12

P203 - 8 X L BO - 1 K6 - AC - 3A 6. 15

P203 - 4 Y L BO - 1 K7 - AC - 3A 6. 15 - M20 6001a02

NOTE Any pumps combinations other the noted standard pumps can be com-posed and ordered in accordance with the valid model identification code.

P203 - 2 X L - 1 K6 - AC - 3A 6. 15 - M10 P203

Basic pump model for grease or oil with 1-3 outlets and 12 VDC or 24 VDC motor

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 = 110-230 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 72585-1 (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)

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Description

6339b04

Fig. 2 Pump components

1 - Reservoir 2 - Pump element 3 - Pressure relief valve 4 - Filling nipple, system

Emergency lubrication possible 5 - Plug, piston detector

6 - 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 oper-ating 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 de-vices.

6340b04

Fig. 3 Quicklub central lubrication pump, 2 l reservoir

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 inte-grated control p.c.b. M08-M23, see fig. 3

- Low-level control for oil not to be combined with inte-grated control p.c.b.

- When the reservoir is empty, an electrical low-level indi-cation will be given.

1 - Low-level control (see also fig. 19, page 15)

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Mode of Operation

Pump Elements with fixed Lubrication output

20002068

Fig. 4 Pump element

1 - Piston 4 - Check valve

2 - Return spring

� 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 lubri-cation points via the metering device, see fig. 5b.

� The following designs are available:

- Piston diameter, K5 ............................................ 5 mm Lubricant output............................... approx. 2 cm³/min

- Piston diameter K6 (standard) ............................ 6 mm Lubricant output............................ approx. 2.8 cm³/min

- Piston diameter, B7 ........................................... 7 mm Lubricant output .............................. approx. 2 cm³/min

- Piston diameter, K7, S7...................................... 7 mm Lubricant output .............................. approx. 4 cm³/min

6001a02

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

1004b04

b) Pump element dispenses lubricant

1 - Eccentric 2 - Piston 3 - Return spring 4 - Check valve

Pump element B7 with bypass check valve

6251b04

Fig. 6 Pump element B7

6250b04

Fig. 7 Sectional diagram - pump element B7

� Pump element B7 suits especially applications in con-taminated environments as the supplied lubricant is pass-ing through a bypass bore (pos. 2) on the check valve (Pos. 1).

� The output is 2 cm³/min.

1 - Check valve 2 - Bypass 3 - Pump piston 4 - Return spring

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Mode of Operation, continuation

Pump Elements with fixed Lubrication output, continuation

1164b95

Fig. 8 Hydraulic diagram of the pump

Check valve

� The check valve

- closes the pressure line during suction stroke.

- prevents the lubricant from flowing back to the housing or reservoir.

1 - Reservoir with stirring paddle 2 - Pump 3 - Check valve, spring-loaded 4 - Pressure relief valve R - Return line p - Pressure line

1163a95

Fig. 9 Arrangement of the pump elements

Arrangement of the pump elements

� If several pump elements are to be installed, the installa-

tion 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.

Pump Elements with adjustable Lubricant output

4158a99

Fig. 10 Adjustable pump element

� The mode of operation (suction and supply phase) is the same as that of the pump elements with an invariable lu-bricant output.

� The lubricant outputs are adjustable from 0.04 to 0.18m3/stroke, or 0.7 to 3cm3/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).

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4159a98

Fig. 11 Sectional view: adjustable element

1 - adjusting spindle SW 16 (SW ~ with over flats)

2 - counternut SW 24

3 - pump element body 4 - gasket 5 - pump cylinder

6 - control piston 7 - delivery piston S - setting dimension

4179a99

Fig. 12 Supply diagram

A - Lubricant output cm3/min B - Lubricant output cm3/stroke S - Setting dimension

Setting of adjustable pump elements

� Unscrew the coupling nut for fixing the pressure relief valve.

� Loosen counter nut (pos.21)) 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

6001a02

NOTE

In order to ensure that the lubricant out-put setting will be as exact as possible, first the actual dimensions “S” of the max. lubricant output must be ascer-tained as follows. The measured differ-ence from the nominal value 29 must be considered for all other settings values (e.g. ± 0.1).

� Unscrew the adjusting spindle (pos.11)) 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.

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Retrofit adjustment of min. lubricant output

� Before the pump element can be adjusted to a small lubri-cant 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 be-tween 25.5 ... 28.5.

� Dimension “S” must be adjusted to the desired value in accordance with the delivery diagram (fig. 12, page 12).

6001a02

NOTE At maximum setting “S“ is 29 ±0.1 mm.

Pressure relief valve

6342b04

Fig. 13 Pressure relief valve

without grease return

6001a02

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.

- 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 indi-cates that the system is malfunctioning.

� Despite existing fault monitoring devices a regular visual and function control must be carried out on the lubrication system.

6001a02

NOTE

Between a malfunction (blockage) and the following fault indication (lubricant leakage; monitoring intermit-tent 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.

6341b04

Pressure relief valve with grease return (optional)

� If the system is blocked, grease will leak from the pres-sure relief valve. This grease quantity is returned to the reservoir.

Fig. 14 Pressure relief valve with grease return

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Pressure relief valve, continuation

6343b04

Fig. 15 Fault indication in the case of a blockage

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.

Return Line Connection

10032618

Fig. 16 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).

Low Level Control

Float magnetic switch for oil

1202a99

Fig. 17 Connection diagram, low level control 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 compo-nent of the float magnetic switch is the float that moves up and down with the liquid reliably on the slide tube. Technical Data Maximum switching capacity ........................ max. 60VA Maximum switching voltage - with power supply AC ................................. max. 230 V Current switched ....................................................... 3 A

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Low Level Control, continuation

Contact protection measures

1201a95

Fig. 18 Contact protection measures

1 - Electromagnetic switch 2 - RC element 3 - Diode 4 - Load

6001a02

NOTE

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.

For grease

6295b04

Fig. 19 Parts of the low level control

1 - Guiding plate with round solenoid (on stirring pad-dle)

2 - Electromagnetic switch (at stirring paddle)

3 - Control cam A - Rotating direction B - Lubricant resistance

6001a02

NOTE

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).

6001a02

NOTE The flashing signal starts only after the solenoid has activated the electromag-netic switch 6 times contact-free.

Reservoir filled

� The stirring paddle rotates clockwise (Pos. A1)) during the operating time.

� When the stirring paddle rotates, the pivoted guiding plate with the round solenoid (pos.11)) is pressed backwards by the resistance of the lubricant (Pos. B1)). The solenoid moves towards the pivot of the stirring paddle. An activa-tion of the solenoid switch (Pos.21)) 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.


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. 31)) has been overtravelled the solenoid remains in the outer position and overruns electromagnetic switch (pos. 2). The solenoid activates the electromagnetic switch con-tact-free, thus triggering a low-level signal.


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Printed Circuit Boards M08-M231) 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: 110-230 VAC

integrated M08-M23

P: 4 to 60 minutes P: 1 to 15 hours Ü: 5 or 30 minutes

236-13870-2

P - Pause time range Ü - Monitoring time

6001a02

NOTE

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.)

6344b04

Fig. 20 Printed circuit board integrated in the housing

� The printed circuit boards are integrated in the pump housing.

1 - control p. c. b. 2 - power supply p. c. b.

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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

6001a02

NOTE

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 “Con-necting Diagram”, page 34). The functional sequence is then controlled by the power supply.

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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 cen-tralized 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)

Voltage ON

Readiness for service

Malfunction

Low level, malfunction

Control p. c. b.

20002441a

Fig. 21 Control p. c. b. 236-13870-2

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Control Unit

Operation

1059a95

Fig. 22 Time sequence diagram

tB - Working hours tP - Various pause times T - Lubrication cycle T1 - Stored pause times T2 - Operating times

� 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 tB, see fig. 22).

� A lubrication cycle consists of one pause time and one operating time. Once the pause time has elapsed, the op-erating time starts running. This lubrication cycle is re-peated 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 op-erating 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 applica-tion. It must be adjusted in accordance with the respective lubrication cycles (see paragraph „To set the pause time“, page 21).

Operating time

00002634

Fig. 23 Piston with mounted detector

� A piston detector (initiator, fig. 23) that has been in-stalled 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 (ei-ther on the main metering device or on the secondary me-tering device).

6001a02

NOTE

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.

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Control Unit, continuation


20002459a

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

Monitoring time

� A fixed monitoring time of maximum 5 or 30 minutes (depending on the jumper position, page 35) runs in paral-lel to the operating time.

6001a02

NOTE

Normally, the monitoring time ends at the same time as the operating time.

� If there is no switching off signal from the piston detec-tor 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 out-put“).

� If the operating time exceeds 5 minutes, the monitor-ing time can be changed from 5 to 30 minutes by re-plugging 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 al-ready 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.

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Time Setting

6345b04

Fig. 25 The cover to the p. c. b.

� To set the pause or operating time, remove the cover on the pump housing.

6001a02

IMPORTANT

After having set the pause time or operat-ing 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.

20002454a

Fig. 26 Pause time rotary switch

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.

6001a02

NOTE

Switch positions 0 and 1are identical and correspond to the shortest adjustable time.

Switch position 0/1 2 3 4 5 6 7 8 9 A B C D E F

Minutes 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60

Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

20002448a

Fig. 27 Preselection of time ranges, jumper position

Factory Setting Pause time jumper position .............................................. 1-15 hours rotary switch position 6 ....................................... 6 hours Monitoring time jumper position ............................................... 5 minutes Monitored lubrication cycles jumper position .......................................................... 1O

6001a02

NOTE

Combination of the jumper positions see page 35.

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Functional Check and Fault Indication

10012434a

Fig. 28 LED for monitoring time and failure display

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“.

6001a02

NOTE

LED display (fig. 33) indicates the same operating state as the external signal lamp.

10012426a

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

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

6001a02

NOTE

Additional lubrication cycles are possible at any time by actuating the pushbutton (pos. 4).

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Functional Check and Fault Indication, continuation

00002429a

Fig. 30 p.c.b. with mounted jumper B/D

Signal Output (M08-M15) Intermitted flashing signal (B) The signal output takes place with the right LED and is im-plemented as follows: � Jumper B/D mounted

System LED (see pos. 3, fig. 29, page 22)

Motor check is lit for approx. 2 seconds

Operating time LED is lit

Fault Flashes according to the present fault indication with different frequency (see paragraph “Functional Check when switch-ing on”, page 22).

00002614

Fig. 31 p.c.b. without jumper B/D

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)

1) Relay has picked up 2) LED is lit permanently

Fault 1) Relay dropped 2) LED is not lit, central lubrication system does not run

20002458

Fig. 32 Acknowledging receipt

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.

6001a02

NOTE

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.

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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)

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 Out-put M08-M15“, page 23).

LED function (M16-M23)

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

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Fault Indication

� In the case of a malfunction the piston detector (initiator, fig. 23, page 19) can no longer record the piston move-ments and therefore, cannot switch the pump off.

� 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).

M08-M15

1053b95

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)

Fault: A Drive motor defective such as: � If the motor does not run when the driving switch or ma-

chine 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 moni-tored 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 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

6001a02

NOTE

The low-level signal is converted into a flashing signal with the a.m. frequency only after 6 motor revolutions.

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Fault Indication, continuation

M16-M23

1162a95

Fig. 36 Readiness for service and fault indication (M16-M23)

A - Readiness for service B - Fault indication

� If any of the following faults occurs, the LED is extin-guished, 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 de-vice 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

6001a02

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 trig-gered.

� In the case of a fault, check whether the central lubrica-tion pump and the connected system are malfunction-ing.

� Eliminate the cause of the fault (see chapter “Trouble-shooting“, 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.

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Maintenance, Repair and Tests

Maintenance

� The maintenance is essentially limited to refilling the res-ervoir 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.

6001a02

NOTE

Whenever work is done on the central-ized lubrication system, particular atten-tion should be paid to absolute cleanli-ness. 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

6347b04

Fig. 37 Fill pump reservoir

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).

6001a02

IMPORTANT

The grease or oil must be free from im-purities and must not be liable to change its consistency in the course of time.

1013A94

CAUTION!

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!

1013A94

CAUTION!

Risk of bursting if the reservoir is overfilled.

When filling the reservoir by means of pumps with a large delivery volume do not exceed the max. filling mark.

6001a02

NOTE

If the reservoir has been completely emptied, the pump may require until 10 minutes before it operates with its full output.

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Maintenance, Repair and Tests, continuation

Repair

Pump � Use only original Lincoln spare parts for repair on the pumps.

� The pump should be returned to the factory for warranty work or major repairs.

Replace pump element

5026a96

Fig. 38 Replace pump element

� 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.

IMPORTANT

Do not leave the piston, spring and washer in the housing as they may block the mo-tor.

6001a02

NOTE

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 para-graph “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.

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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 Technical Description of the respective printed circuit board (see paragraph „Opera-tional Test / To Trigger an Additional Lubrication Cycle“, page 22).

To Check the pressure relief valve

6348b04

Fig. 39 To check the pressure relief valve

1st option � Connect the pressure gauge (0-600 bar; 0-8708 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 604-36879-1 to the safety valve and check the open-ing 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.

6001a02

IMPORTANT

Do not connect the pressure gauge di-rectly to the pump element. High pres-sure 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.

1 - Hose line, min. length 1m 2 - T-piece 3 - Pressure gauge 4 - Relief cock

Functional Check of the p.c.b.

6001a02

NOTE

See paragraph “Functional Check and Fault Indication“, page 22.

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Troubleshooting

6001a02

NOTE

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: Remedy: � Power supply interrupted

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, re-place the motor.

� p.c.b. defective � Check the function of the p.c.b. (see paragraph “Opera-tional 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 meter-ing device.

� Unscrew the piston detector.

� Check the piston detector. For this, insert a metallic pin into the borehole of the de-tector. 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 inter-rupted

� Check the cable connections to the pump.

� If necessary, replace the piston detector with the connec-tor.

� p.c.b. defective � Check the function of the p.c.b. (see paragraph „ Opera-tional Test / To Trigger an additional lubrication cycle“, page 22).

� If necessary, replace the p.c.b..

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Troubleshooting, continuation

Fault: The pump does not deliver the lubricant

Cause : Remedy:

6001a02

NOTE

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.

6001a02

NOTE

Depending on the ambient temperature and/or sort of lubricant it may take 10 min-utes 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 re-lief valve. The lubricant must penetrate without air bub-bles.

6001a02

NOTE

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.

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Technical Data

PUMP

Admissible operating temperature ............... -40° C to 70° C1) 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 40050 T9

6001a02

1) NOTE The pump is designed for the above mentioned temperature range. The lubri-cants 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, K5......................................................... 5 mm - Lubricant output ...................................... approx. 2 cm³/min Piston diameter, (Standard) K6....................................... 6 mm - Lubricant output ................................... approx. 2.8 cm³/min Piston diameter, B7......................................................... 7 mm - Lubricant output ...................................... approx. 2 cm³/min Piston diameter, K7, S7 .................................................. 7 mm - Lubricant output ...................................... approx. 4 cm³/min max. operating pressure . ........................................... 350 bar Connection thread ........................................................ G ¼“ - suitable for tube DIA ................................................... 6 mm

Pump element with adjustable lubricant output

KR ..................................................... 0.04 to 0.18 cm³/stroke ...................................................................... 0.7 to 3 cm³/min Connection thread ........................................................ G ¼“ - suitable for tube DIA ................................................... 6 mm - suitable for tube DIA ................................................... 8 mm

6001a02

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 lubri-cant outputs. Any system design must be based on the above values.

PRESSURE RELIEF VALVE

SVETVT-350-G 1/4A-D6 .................................... 624-28894-1 SVETVT-350-G 1/4A-D8 .................................... 624-28774-1

TORSION TORQUES

Install pump .................................................................. 18 Nm Electric motor on housing ............................................ 12 Nm Pump element in housing ............................................ 25 Nm Closure plug in housing ............................................... 12 Nm Return line connector in housing ........................ 10 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 ............................5.4 kg - Pump 203, version 1A1.10 ..........................................6.5 kg - Pump 203, version 2A1.10 ..........................................7.1 kg 4 l reservoir, standard design (1.5 kg)

- Pump 203 without connection cable ........................... 8.3 kg - Pump 203, version 1A1.10 ......................................... 9.3 kg - Pump 203, version 2A1.10 ......................................... 9.9 kg

8 l reservoir, standard design (1.5 kg)

- Pump 203 without connection cable ........................... 8.6 kg - Pump 203, version 1A1.10 ..........................................9.6 kg - Pump 203, version 2A1.10 ........................................10.2 kg In the case of pump versions deviating from those mentioned, add the weights of the following components to the men-tioned weights: - per pump element ..................................................... +0.2 kg - per pressure relief valve ........................................... +0.1 kg - 10 m monitoring cable, 5-wire (microprocessor) 2A4.13 ......................................... +1.1 kg - 10 m monitoring cable, 4-wire (microprocessor) 2A4.12 ......................................... +0.4 kg - Connection cable with piston detector ...................... +0.1 kg - Reservoir version ”Filling from top” (only 2 l) 3) ....... +0.15 kg - 2 l flat-type reservoir ................................................. +0.5 kg

6001a02

3) NOTE

The 4l and 8l reservoirs have the stan-dard design ”filling from top”. Also avai-lable with reservoir closed on the top.

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Technical Data, continuation

Electrical Data

PUMP

Input AC

Input voltage ................. 110-230 VAC ±10% ; 50/60 Hz ±5% Input current ........................................... 200 mA at 230 VAC Starting current impact ................................................. < 18 A Fuse ..................................................... T 1,25 A/250 V intern

6001a02

NOTE

If internal fuse has to be replaced, use only the original type.

Output

Output voltage, internal ..................................... 24 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 / 11.93 / EN 60950 / IEC 950, EN 60204

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 UON max.) EMC

Radio interference suppression ......................................... VDE 0875 T 11, EN 55011 class A Emitted interference ................................. acc. to EN 50081/2 Noise immunity ........................................ acc. to EN 50082/2

6001a02

NOTE

The emitted interference meets the re-quirements for the industrial sector, if used in the residential sector this may possibly lead to interference.

Motor

DC gear motor (interference-suppressed) - Operating voltage .................................................... 24 VDC - Max. current input ........................................................... 3 A - Speed ........................................................ approx.17 U/min

Operating Mode

6001a02

IMPORTANT

Suitable for interval operation only, not for permanent operation!

Operating voltage > 120 VAC: - max. operating time ............................................ 30 minutes - min. pause time .................................................... 4 minutes Operating voltage < 120 VAC: - max. operating time .............................................. 8 minutes - min. pause time .................................................. 16 minutes

PRINTED CIRCUIT BOARD

Rated voltage ............................................................ 24 VDC Operating voltage ..................................................... 9 to 30 V Residual ripple in relation - With the operating voltage ............... ±5% acc. to DIN 41755 Output motor ....................... transistor 7A / short-circuit proof Reverse voltage protection ............. Operating voltage inputs .......................... are protected against polarity reversal Temperature range ....................................... -25 °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 condensa-tion, it has been covered with a protective varnish. All the printed circuit boards comply with the EMC (Electro-magnetic compatibility) guidelines for road vehicles acc. to DIN 40839 T1, 3 and 4. Emitted interference ....................... acc. to EN 55011 / 03.91 and ................................................... acc. to EN 50081-1 / 01 Noise immunity .......................... acc. to prEN 50085-2 / 1994

Time Setting

- Pause time either ................................................ 4, 8, 12, ... 60 minutes or ........................................................... 1, 2, 3, … 15 hours - Operation time is switched off via the piston detector - Monitoring time either .................................................................... 5 minutes or ........................................................................ 30 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

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Connection Diagram

6001a02

NOTE

Consider the safety instructions, page 6!

6373a04

Fig. 40 Connection diagram Quicklub 203 with monitoring of the divider blocks (industry), connectors AMP

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Combination of the jumper positions – Survey

Pause time ranges Possibilities of

preselection Connection of the

supply voltage

Signal indication in the case of faults

Signal output h min

Monitoring time ranges (min)

Number of the monitored lubri-cation circuits

Setting only

terminal 15

terminal 15 + 30

intermit-tend

perma-nent 1 - 15 4 - 60 5 30 1 2

Jumper position

1175a95

1174a95

1177a95

1176a95

1186a95

1187a95

1190a95

1189a95

1182a95

1183a95

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

Co

mb

inat

ion

nu

mb

er

M23 X X X X X

1188a95

Fig. 41 Schematic view of the p.c.b.

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Terminals of the p.c.b.

+ 1

- 1 and 2

+

lubrication cycle

2

-

+ low level control

+

- motor

external signal lamp

additional lubrication

machine contact

+

- power supply

20002460

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

6001a02

NOTE

Thighten pump models wih 2 l - flat, 4 L - and 8 L reservoir with three fastening screws (see pt. R 9,5).

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Dimensions - 2 l reservoir

6356b04

Fig. 44 Dimensions - 2 l reservoir

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Dimensions - 2 l reservoir with filling from top

6357b04

Fig. 45 Dimensions - 2 l reservoir with filling from top

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1169b04


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1170b04


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Manufacturer´s Declaration

D GB F I Herstellererklärung

im Sinne der EG-Richtlinie Maschinen 98/37/EG, Anhang II B

Declaration by the manufacturer as defined by machinery directive 98/37/EEC Annex II B

Déclaration du fabricant conformément à la directive 98/37/CEE, annexe II B

Dichiarazione del costruttore ai sensi della direttiva 98/37/CEE in materia di macchinari, Appendice II B

Hiermit erklären wir, dass die Bauart von

Herewith we declare that the supplied model of

Par la présente, nous déclarons que le produit ci-dessous

Si dichiara che il prodotto da noi fornito

Product: Pump 203 with control p.c.b. M08-M23

in der von uns gelieferten Ausführung zum Einbau in eine Maschine bestimmt ist und dass ihre Inbetriebnahme solange untersagt ist, bis festgestellt wurde, dass die Maschine, die in das o.g. Produkt eingebaut werden soll, den Bestimmungen der oben genannten Richtlinie –einschließlich deren zum Zeit-punkt der Erklärung geltenden Änderungen – entspricht.

is intended to be incorporated into machinery covered by this directive and must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the above mentioned directive – including all modifications of this directive valid at the time of the declaration.

dans l’exécution dans laquelle nous le livrons, est destiné à être installé sur une machine, et que sa mise en service est interdite tant qu’il n’aura pas été constaté que la machine sur laquelle il sera installé est conforme aux dispositions de la directive ci-dessus, y compris les modifications qui y auront été apportées et qui seront valides à la date de la déclaration.

è destinato all' installazione su di un macchinario e che la sua messa in funzione non sarà autorizzata fino a quando non sarà stata accertata la conformità del macchinario, sul quale esso dovrà essere installato, in relazione alle disposizioni della direttiva 98/37/CEE – comprese tutte la rettifiche di questa direttiva al momento della dichiarazione.

Angewendete harmonisierte Normen, insbesondere

Applied harmonized standards in particular

Normes harmonisées, notamment

Norme armonizzate applicate in particolare

Standards: EN 292-1; EN 292-2; EN 809

17.07.2002 Z. Paluncic (Datum / Unterschrift) (date / signature) (date / signature) (data/firma)

GR E P NL DK ∆ηλωση του κατασκευασ του συµφ. µε τις προδιαγρ αφες: 98/37/ΕΟΚ, παρ. ΙΙ Β

Declaración del fabricante conforme con la Directiva CE sobre máquinas 98/37/CEE, Anexo II B

Declaração do Fabricante segundo directiva CE 98/37/CEE, Anexo II B

Verklaring van de fabrikant inzake de richtlijn betreffende machines, (98/37/EEG, bijlage II B)

Fabrikantens erklaring i henold til EF-lovgivning om maskiner 98/37/EØF bilag II b

∆ια του παροντος σας γνω− στοποιουµε, οτι το προιον

Por la presente, declaramos que el modelo suministrado

Em anexo declaramos que o modelo fornecido

hiermede verklaren wij, dat de Hermed erklares, at

Product: Pump 203 with control p.c.b. M08-M23

προοριζεται για τοποθετηση εντος µηχανηµατος, και οτι δεν επιτρεπεται να τεθει σε λειτουργια µεχρις οτου διαπιστωθει, οτι το µηχανηµα εντος του οποιου προκειται να τοποθετηθει ανταποκρινεται στις προαναφεροµενες ισχυουσες προ −

διαγραφες (συµπεριλαµβανο−µενων των αλλαγων που ισχυ−ουν και που εγιναν στο χρονι−κο αυτο διαστηµα).

es destinado a ser incorporado en una máquina y que su puesta en servicio está prohibida antes de que la máquina en la que vaya a ser incorporado haya sido declarada conforme a las disposiciones de la Directiva en su redacción 98/37/CEE – incluso las modificaciones de la misma vigentes a la hora de la declarción.

deverá ser incorporado na maquinaria coberta por esta directiva e não poderá ser colocado em serviço até a maquinaria na qual é para ser incorporado for declarada em conformidade com as provisões da directiva acima mencionada / incluindo todas as modificações desta directiva válida desde a emissão desta declaração.

ertoe bestemd is, ingebouwd te worden in een machine en dat een inwerkstelling verboden is, voordat vastgesteld is, dat de machine, waarin deze machine wordt ingebouwd, in overeenstemming met de bepalingen van de richtlijn 98/37/EEG – ingesloten de tot dit tijdstip geldende veranderingen van deze richtlijn - verklaard is.

er bestemt til inkorpoering i en maskine og at igangsætningen forbydes indtil der er konstateret, at maskinen, som skal inkorporeres i denne maskine, er bragt i overensstemmelse med alle relevante bestemmelser, samt ændringer gældende på deklarationstidspunktet.

Προσθετα προς εφαρµογην χρησιµοποιηθησες εναρµον ισµενες προδιαγραφες

Normas armonizadas utilizadas, particularmente

Normas harmonizadas utilizadas, em particular

Gebruikte geharmoniseerde normen,namelijk

Harmoniserede standarder, der blev anvendt,i særdeleshed

Standards: EN 292-1; EN 292-2; EN 809

17.07.2002 Z. Paluncic

(ηµεροµηνια / υπογραφη) (fecha / firma) (Data / assinatura) (Datum/ handtekening) (dato/underskrift)

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America: Europe/Africa: Asia/Pacific: Lincoln Industrial One Lincoln Way St. Louis, MO 63120-1578 USA Phone: (+1) 314 679 4200 Fax: (+1) 800 424 5359

Lincoln GmbH & Co. KG Heinrich-Hertz Straße 2-8 69190 Walldorf, Germany Tel: (+49) 6227 33-0 Fax: (+49) 6227 33-259

Lincoln Industrial Corporation 51 Changi Business Park Central 2 # 09-06 The Signature Singapore 486066 Phone: (+65) 6588-0188 Fax: (+65) 6588-3438 Email: [email protected]

© Copyright 2004 Printed in Germany Web site: www.lincolnindustrial.com

Lubricants

6001a02

IMPORTANT

Absolute cleanness is essential when handling lubricants. Impurities will remain suspended in the lubricant and cannot settle. This will result in damage to the lubrication system and thus to the bear-ing.

The Quicklub pump can dispense commercial greases up to NLGI grade 2 or mineral oils of at least 40 mm²/s (cST) at 40 °C. The proven lubricants (see following tables) have been tested by us with regard to their transportability and bleeding behavior. We can recommend them for an application up to the indicated minimum delivery temperature in Quicklub lubrication systems by Lincoln& Co. KG. During the tests these lubricants did not cause any damage due to incompati-bility with the material used by us. The composition of the lubricants, their behavior during the transport and their com-patibility with other material are not known to us.

The lubricants we recommend on the basis of the manufac-turer’s data sheet (see following tables) can be used in our lubrication systems up to the indicated minimum delivery temperature. Lubricant recipes may change. In case of doubt, send your request for more information to the manufacturer of the cen-tralized lubrication system. This refers in particular to lubri-cants with more than 3% graphite that are transportable in lubrication systems only conditionally. The lubricants released by us have not been tested with re-gard to their long-term behavior.

6001a02

IMPORTANT The manufacturer of the centralized lubrication system can accept no liability for: - damages due to the use of greases that are not or only conditionally transportable in centralized lubrication systems. - damages on parts of the centralized lubrication system caused by chemical or biological changes of the lubricant used. - damages due to the incompatibility with other materials. The liability is limited to transportable lubricants in centralized lubrication sys-tems.

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Lubricants, continuation

Quicklub List of Lubricants

6001a02

IMPORTANT

Use lubricants with solid matter additives only after having consulted the manufacturer of the sys-tem!

Proven lubricants:

Manufacturer Designation Base soap Min. delivery temperature

AUTOL Top 2000 Ca-complex -10 °C AUTOL Top 2000 W Ca-complex -20 °C BP C1 Multipurpose grease Ca -20 °C BOSCH-REXROTH Dynalub 510 Li -15 °C BOSCH-REXROTH Dynalub 520 Li -20 °C ELKALUB GLS 135/N2 Li -15 °C FUCHS-LUBRITECH Stabil Eco EP2 Li/Ca -25 °C FUCHS Renocal FN 745 Ca-12-OH-stearat -25 °C FUCHS Renocal FN3 Ca -20 °C FUCHS Renolit LZR 2 H Li -20 °C FUCHS Renolit HLT 2 Li -25 °C MOBIL Mobilith SHC 100 Li-complex -25 °C MOLYKOTE TTF 52 inorganic thickener -30 °C OPTIMOL Longtime PD 2 Li-12-OH-stearat -20 °C OPTIMOL OLIT CLS Li/Ca -15 °C SHELL Retinax EPL 2 Li-12-OH-stearat -10 °C WESTFALEN Gresalit ZSA 2 Li-12-OH-stearat -15 °C

Lubricant recommendations based on the manufacturer’s data sheet:

Manufacturer Designation Base soap Min. delivery temperature

AGIP F1 Grease 24 Ca -15 °C ARAL Multipurpose grease ZS 1/2 Li/Ca -20 °C BP Energrease LC 2 Li-complex -15 to -10 °C BP Energrease MP-MG 2 Ca-complex -5 °C CASTROL / TRIBOL Molub Alloy 6780 Li-12-OH-stearat -30 to -25 °C CASTROL CLS - Grease Li/Ca -25 °C DEA Glissando 20 Li-12-OH-stearat -15 to -10 °C ESSO Ronex Extra Duty 2 Li-complex 5 °C ESSO Ronex MP2 Li-complex -5 °C ESSO Beacon EP2 Li -5 °C ESSO Cazar K2 Ca -15 °C FIAT LUBRIFICANTI Comar 2 Li -25 °C FINA CERAN LT Ca-complex -20 °C FINA CERAN WR2 Ca-complex -10 °C KLÜBER Centoplex 1 DL Li/Ca -20 °C KLÜBER Isoflex NBU 15 Ba -25 °C MOBIL Mobilgrease XHP 221 Li-complex -10 °C MOBIL Mobilgrease XHP 461 Li-complex -10 °C MOBIL Mobilgrease XHP 222 Li-complex -5 °C MOBIL Mobilith SHC 220 Li-complex -20 °C SHELL Alvania EP(LF) 1 Li-12-OH-stearat -15°C +/- 5°C SHELL Alvania EP(LF) 2 Li-12-OH-stearat -10°C +/- 5°C SHELL Alvania RL2 Li-12-OH-stearat -15°C +/- 5°C SHELL Retinax CS Li -20 °C SHELL Retinax LX 2 Li -5°C +/- 5°C SHELL Retinax HDX 2 Li/Ca -10°C +/- 5°C TEXACO Premium RB Li -20 °C ZELLER & GMELIN DIVINOL Lithogrease G 421 Li-complex -15 °C

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Lubricants, continuation

Quicklub List of Lubricants, continuation

6001a02

IMPORTANT

Use lubricants with solid matter additives only after having consulted the manufacturer of the sys-tem!

Biodegradable lubricants

Proven lubricants:

Manufacturer Designation Base soap min. delivery temperature

ARAL Aralub BAB EP 2 Li/Ca -25 °C BP Biogrease EP 2 Li/Ca -25 °C FUCHS-LUBRITECH Stabyl ECO EP 2 Li/Ca -25 °C



AUTOL Top Bio 2000 Ca -25 °C AVIA Biogrease 1 Li up to 0 °C DEA Dolon E 2 Li -15 °C FUCHS Plantogel 2 S Li/Ca -15 °C KLÜBER Klüberbio M72-82 Polycarbamide -20 °C

Lubricants for the food & beverage industry



ARAL EURAL Grease EPF 2 Al-complex -5°C BREMER & LEGUIL RIVOLTA F.L.G 4 – 2 Al-complex -20 °C ELKALUB GLS 364 organic thickener -10 °C ELKALUB GLS 367/N2 inorganic thickener -5°C ELKALUB GLS 380/N1 Al-complex -10 °C ELKALUB GLS 380/N2 Al-complex -5°C FUCHS RENOLIT G 7 FG 1 Bentonite -5°C FUCHS-LUBRITECH GLEITMO 585 M (KTW-drinking water release) Li -10 °C INTERFLON FIN FOOD GREASE EP Al-complex -5°C KLUEBER PARALIQ GA 343 Al-complex -10 °C KLUEBER KLUEBERSYNTH UH1 14-151 Al-complex -20 °C MOBIL MOBILGREASE FM 462 Al-complex -15 °C Nordischer Maschinenbau BAADER

Special grease GLS 380/N3 Al-complex -5°C

OKS 470 Li-12-OH-stearat -15 °C OPTIMOL OBEEN UF 1 Al-complex -15 °C OPTIMOL OBEEN UF 2 Al-complex -10 °C RHENUS NORPLEX AFD 2 Al-complex -5°C RHENUS NORPLEX AFP 2 Al-complex -5°C RHENUS NORPLEX AFS 2 Al-complex -25 °C RHENUS NORPLEX AFW 2 Al-complex -5°C SHELL CASSIDA Grease EPS 1 Al-complex -15 °C SHELL CASSIDA Grease EPS 2 Al-complex -10 °C TOTAL LUBRIPLATE FGL 2 Al-complex -5°C TRIBOL MOLUB-ALLOY FoodProof 823-2 FM Al-complex -15 °C TRIBOL MOLUB-ALLOY 9830 high-temperature grease PTFE 0°C

ИТЦ ТЕХСЕРВИС - Quicklub · 2017-10-01 · 2.1A-30005-A04 Page 4 of 44 LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49

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