Lubrication System QLS 301

User Manual

Installation and Operation Instructions

Lubrication System QLS 301

4197a99

Form 403013

6093b03

U.S. Patent-No. 6,244,387, German Registration Design No. 29923765.6

810-55230-1

2.1A-38006-E05

User Manual


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.

© 2005 by

LINCOLN GmbH & Co. KG

Postfach 1263

D-69183 Walldorf

Phone: +49 (6227) 33-0

Fax: +49 (6227) 33-259

Page 2 of 48 2.1A-38006-E05 Form 403013

User Manual


Table of Contents

Page

Introduction ..................................................................... 4

Explanation of Symbols Used ............................................ 4

User’s Responsibility ......................................................... 4

Environmental Protection .................................................. 4

Service .............................................................................. 4

Glossary ............................................................................ 4

Safety Instructions .......................................................... 5

Appropriate Use ................................................................ 5

Misuse ............................................................................... 5

General Safety Instructions ................................................ 5

Regulations for Prevention of Accidents ............................ 5

Operation, Maintenance and Repair .................................. 5

Operation/Maintenance ................................................ 6

Exclusion Liability .................................................... 6

Installation ......................................................................... 6

Installation Instructions .................................................. 7

Pump ................................................................................. 7

SSV-Lubricant Metering Device ........................................ 7

Adjusting the output by Crossporting of outlets .................. 7

Single Output ............................................................... 7

Double Multiple Outputs .......................................... 7

Check valves ............................................................... 7

Returning of lubricant quantities ........................................ 8

Lubrication points .............................................................. 9

Installing Zerk-Locks onto Grease Fittings ........................ 9

Connection of Feed Lines ................................................ 10

Filling of Reservoir............................................................ 10

Identification Code

VDC ................................................................................. 11

VAC ................................................................................. 12

Electrical Connecting Diagrams ................................... 13

VAC ................................................................................. 13

VDC ................................................................................. 15

Description

QLS 301 with back position of the SSV divider block ...... 17

QLS 301 with bottom position of the SSV divider block ... 17

QLS 301 with external SSV divider block ........................ 18

Page

Operation ........................................................................ 19

Pump ............................................................................... 19

Pressure Relief Valve ...................................................... 19

Display of the Membrane Keypad .................................... 19

Monitoring time/ malfunction ............................................ 20

Operator keys of the keypad ............................................ 21

Setting the pause time................................................. 21

Display of information regarding the set pause time.... 22

Changing to the different programming levels ............ 22

Monitoring Relay .............................................................. 22

Setting and Operation ..................................................... 23

Factory Settings ............................................................... 23

Operator Keys .................................................................. 23

Display mode ................................................................... 24

Programming mode ......................................................... 25

Operating mode ............................................................... 30

Maintenance, Repair and Tests

Maintenance .................................................................... 33

To fill reservoir ............................................................ 33

Repair .............................................................................. 34

Functional Test ................................................................ 34

Troubleshooting

Pump of the QLS 301 system ........................................... 35

SSV Metering Device ....................................................... 37

Technical Data ................................................................ 39

QLS 301, General ...................................................... 39

Electrical Data ............................................................ 39

Time Setting ............................................................... 39

Relay for Malfunction .................................................. 39

Accessory Kits ............................................................ 39

Dimensions ...................................................................... 40

SSV Divider Blocks ..................................................... 40

Service Parts .................................................................. 41

Version with bayonet plug ................................................ 41

QLS 301 with bottom mounted SSV divider block and square-type plug ....................................................... 42

QLS 301 with back mounted SSV divider block and square-type plug ....................................................... 44

Option for Metrical Fittings ........................................... 46

EC Declaration of Conformity ....................................... 47

Form 403013 2.1A-38006-E05 Page 3 of 48

User Manual


Introduction

Explanation of Symbols Used

The following description standards are used in this manual:

Safety Instructions

Structure of safety instructions:

Pictogram

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

Â Procedural instruction

- 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 following text is not observed:

ATTENTION refers to faults or damages on

CAUTION

machines. refers to bad damages and possible injuries.

WARNING

NOTE

IMPORTANT

refers to possible dangerous injuries. indicates improved operation of the device. indicates special operating features of the device.

Example:

ATTENTION!

1013A94

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.

User's Responsibility

To ensure the safe operation of the unit, the user is responsible for the following:

1. The pump / system shall be operated only for the intended use (see next chapter "Safety Instructions") and its design shall neither be modified nor transformed.

2. The pump / system shall be operated only if it is in a proper functioning condition and if it is operated in accordance with the maintenance requirements.

3. The operating personnel must be familiar with this Owner

Manual and the safety instructions mentioned within and observe these carefully.

The correct installation and connection of tubes and hoses, if not specified by Lincoln GmbH & Co. KG, is the user's responsibility. Lincoln GmbH & Co. KG will gladly assist you with any questions pertaining to the installation.

Environmental Protection

Waste (e.g. used oil, detergents, lubricants) must be disposed of in accordance with relevant environmental regulations.

Service

The personnel responsible for the handling of the pump / system must be suitably qualified. If required, Lincoln GmbH

& Co. KG offers you full service in the form of advice, on-site installation assistance, training, etc. We will be pleased to inform you about our possibilities to support you purposefully.

In the event of inquiries pertaining to maintenance, repairs and spare parts, we require model specific data to enable us to clearly identify the components of your pump / system.

Therefore, always indicate the part, model and series number of your pump / system.

Glossary

Lubricating time

Operating cycle

=

=

Operating time

Lubrication cycle

Page 4 of 48 2.1A-38006-E05 Form 403013

User Manual


Safety Instructions

Appropriate Use

The lubrication system QLS 301 has been designed for initial and retrofit installation. It has been designed for:

1. the automatic lubrication of machines and systems

2. the automatic lubrication of commercial vehicles and construction machines

3. the automatic lubrication of hydraulically driven units and devices.

The lubrication system QLS 301 is able to deliver greases up to NLGI grade 2 or fluid greases of NLGI grade 000 or 00.

Use the QLS 301 exclusively to supply lubricants.

The QLS 301 is adequate for intermittent operation only.

The QLS 301 is adequate for feeding max. 18 lube points per operating cycle.

Do not use QLS 301 with bottom-mounted SSV metering device for mobile applications. Do not install the system with machines exposed to shock.

Misuse

Any use of the QLS 301 that is not expressly mentioned in this User Manual will be regarded as misuse.

If the QLS 301 is used or operated in a different manner other than specified, any claim for warranty or liability will be null and void.

NOTE

6001a02

If personal injury or material damage occurs as a result of inappropriate operation, e.g. if the safety instructions are ignored or resulting from an incorrect installation of the QLS 301, no claims or legal actions may be taken against

Lincoln GmbH & Co. KG.

General Safety Instructions

Lubrication systems QLS 301

- are designed state-of-the-art.

- can be assembled for safe operation.

- must be regularly refilled with clean lubricant.

Incorrect use may result in bearing damage caused by poor or over-lubrication.

Do not over-pressurize reservoir when filling the pump.

Refill QLS 301 pump with clean lubricant.

Each outlet needed must be equipped with an appropriate check valve.

IMPORTANT

Do not paint the pump. Before painting a machine or commercial vehicle, remove or cover the pump completely.

6001a02

Unauthorized modifications or changes to an installed system are not recommended and will void warranty. Any modifications must be subject to prior consultation with the manufacturer of the QLS 301.

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.

Operation, Repair and Maintenance

1013A94

ATTENTION!

Malfunction because of dirt!

When executing any maintenance or repair works on the QLS 301, ensure absolute cleanliness.

CAUTION!

Switch off the power supply before beginning maintenance or repair work.

4273a00

Repair

Repairs should only be performed by authorized personnel who are familiar with the instructions.

Form 403013 2.1A-38006-E05 Page 5 of 48

User Manual


Safety Instructions, continuation

Operation, Repair and Maintenance, continuation

Operation/Maintenance

Lubrication systems QLS 301

must operate with mounted pressure relief valve, only.

must operate only with mounted or connected SSV divider blocks.

must be regularly filled with clean and air-free lubricant.

operates automatically. However, a regular check (approximately every 2 weeks) should be made to ensure that lubricant is being dispensed from all lubricant points.

Operation with bayonet plug

CAUTION!

If the protective-conductor terminal is not connected or interrupted, dangerous touch voltages may occur on the equipment!

4273a00

Protective measures to be applied for the appropriate operation with bayonet plugs:

"Functional extra-low voltage with safe isolation" /

"Protective Extra-Low Voltage" (PELV)

Standards: EN60204 Part1:1992 / IEC 204-1:1992, modified

DIN VDE 0100 Part 410 / IEC 364-4-41:1992

(see pages 15 to 19)

Disposal

Used or contaminated lubricants must be disposed of in accordance with local environmental regulations, see technical data sheets of lubricants.

Exclusion of Liability

The manufacturer of the centralized lubrication system will not accept any liability for:

damage caused by insufficient lubricant and irregular refilling of pump

damage due to the use of greases which are not or are only conditionally pumpable in centralized lubrication systems

damage caused by the use of contaminated lubricants

damage caused by inadequate disposal of used or contaminated lubricants

damage caused by unauthorized modification of system components

damage caused by the use of unapproved parts (voids the pump warranty)

Installation

IMPORTANT

Do not remove, modify or alter any safety equipment already installed on the machine, the construction machine or the commercial vehicle.

6001a02

If necessary, these devices may be removed temporarily during the installation of the pump.

The devices must be properly put back in place after the installation of the pump.

Use only original spare parts or spare parts authorized by

Lincoln.

Keep pump QLS 301 away from sources of heat (see

Operating Temperature Specification, Technical Data).

Provide access to fill, clean and visually monitor the pump operation.

IMPORTANT

6001a02

Adhere to the installation instructions of the vehicle or machine manufacturer as regards all drilling and welding procedures. Observe the specified minimum distances between bores and upper/lower rim of the frame or between the bores.

4273a00

4273a00

CAUTION!

The QLS 301 may only be installed 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 lockout device for isolating and disconnecting the QLS

301. Before beginning the installation work, disconnect the electrical supply.

WARNING!

Failure to observe the safety instructions, e. g. touching electrically charged parts when the system is opened, or improper handling of the

QLS 301 may cause serious injury or

death.

If the values specified in the Technical

Data are exceeded, the device may overheat. It may damage the QLS 301 and thus impair the electric safety.

Page 6 of 48 2.1A-38006-E05 Form 403013

User Manual


R

Pump

SSV Metering Device

1014b00

Fig. 1 Single double and triple lubricant output, on back-mounted metering devices

0x-3x Output (single, double, etc.)

A Clamping ring of the check valve

Return to reservoir

Fig. 3 Check valve, push-in type

A Clamping ring (brass)

Installation Instructions

Use drilling template to mark and drill mounting holes of the

QLS 301. Drilling template and mounting bolts are included in the package.

Fig. 2 Closure plug, also provided in the accessory kits

4163a98

4180a02

Adjusting the output by cross-porting of outlets

Single Output

A single output is the lubricant quantity fed to the lube point by a piston per stroke and outlet port. It amounts to ap-

proximately 0.2 cm³, see outlet 6, fig. 1.

Double or Multiple Outputs

Outputs can be increased by simply plugging the unused outlet ports with closure plugs (fig. 2, provided in the accessory kit).

Lubricant from a plugged outlet is redirected to the next outlet on the same side of the SSV divider block in descending numerical order (see fig.1).

Example, see fig. 1:

By closing

- of outlet 4, outlet 2 receives the double quantity.

- of outlets 5 and 3, outlet 1 receives the triple amount of lubricant. The connecting conduit from outlet line 1 to outlet line 2 and to the return line (R) is closed by clamping rings (A) of the check valve.

Unused lubricant can be internally fed back to the reservoir, see paragraph ‘’direct internal feed back feature”.

6001a02

NOTE

Do not plug outlets number 1 or 2

(horizontally positioned outlets) on bottom-mounted lubricant metering devices SSV 8, 12 and 18.

Do not plug outlets number 1 or 2 on externally mounted metering devices.

Closure plugs

Â Install a closure plug in each outlet port that is not required, see fig. 1 or 4.

Closure plugs are used in fig. 1 and 4 as follows:

- Fig. 1 outlets 3, 4 and 5

- Fig. 4 (page 8) outlets 1, 2, 4 and 5

Check valves

Â For feed lines (diameter 6x1.5 mm, 1/4” I.D., provided in the accessory kits) use check valves with standard collar and knurled flange.

Â Install a check valve in each outlet port that is required, see fig. 1 or 4. Observe paragraph “Direct (internal) feedback feature” (see page 8).

Check valves are used in fig. 1 and 4 as follows:

- Fig. 1

- Fig. 4 (page 8) outlets 1, 2 and 6 outlets 3 and 6

Form 403013 2.1A-38006-E05 Page 7 of 48

User Manual


Installation Instructions, continuation

Fig. 4 Internal feedback of supplied lubricant, only on backmounted SSV metering devices

0x-2x Output (single, double, etc.)

4188b99

A Clamping ring of the check valve

6001a02

NOTE

Maximum internal combination of outlets:

SSV 6 = 3

SSV 12 = 6

SSV 18 = 9

Further combinations are possible outside the metering device by means of a tee-piece only.

Direct (internal) feedback feature

All pumps with back-mounted SSV metering device have the capability to feed back unused lubricant internally from closed outlets directly to the reservoir (see pos.

R fig. 1, 4).

This procedure will start automatically, if outlet port 2 is plugged with a closure plug. All pumps have capability to feed back the lubricant directly to the reservoir from even

and odd outlets via the passage from outlet 1 to outlet 2.

When feeding back, always start with plugging the outlets

with the smallest outlet numbers, e.g. 2, 4, 6... or 1, 3,

5... plus outlet 2. In fig. 4 the outputs of outlets 1, 2 and 4

(3xR) are fed back to the reservoir.

The remaining outlets are to be used for the connection to the lube point or for increasing the lubricant output (double or triple), see fig.1.

CAUTION!

If outlet 2 is connected to a lube point, then never close outlet 1, see clamping ring (A) in outlet 2, fig. 1.

1013A94

6001a02

NOTE

To feed back unneeded lubricant quantities from bottom-mounted metering

devices to the reservoir, connect unneeded outlet via the feed line to plug

(pos. R, Fig 20, page 19) for external return line.

Page 8 of 48 2.1A-38006-E05 Form 403013

User Manual



Lubrication Points

Installing Quicklinc fittings into lube points

Remove lubrication fitting from lube point and install appropriate Quicklinc fitting into the bore of the lube point.

Installing Zerk-Lock onto Lube Fitting

4200a99

Fig. 5 Place the Zerk-Lock body over the filler fitting

4201a99

Fig. 6 Installation of Zerk-

Locks with staking tool

Fig. 7 Screwing Quicklinc fitting into the Zerk-Lock body

4202a99

The Zerk-Lock fitting consists of the Zerk-Lock body, insert and a Quicklinc fitting.

Â Place the Zerk-Lock body over the lube fitting and place the staking tool firmly against the Zerk-Lock insert. (Staking tool is included in the accessory kits).

Â Strike the tool sharply with a hammer until the Zerk-Lock insert partially crimps onto the grease fitting.

Â Screw the Quicklinc fitting into the Zerk-Lock body and tighten until parts resist further tightening (about 1-1/2 turns).

NOTE

Quicklinc hex. is 12 mm. Zerk-Lock body hex is 1/2 ’’.

6001a02

Â Move the Zerk-Lock and tube fitting from side to side on the lubrication fitting to insure the Zerk-Lock is firmly seated.

Form 403013 2.1A-38006-E05 Page 9 of 48

User Manual



Connection of Feed Lines

Fig. 8 Feed line installed in the Quicklinc fitting

4203a99

4157a98

Fig. 9 Feed line insert into the fitting up to the next white mark

Filling of reservoir

Â Measure, cut and route the feed lines included in the accessory kit.

NOTE

6001a02

Avoid sharp bends of the plastic tubing and the moving parts of the machine that could damage the lubrication lines. Minimum bending radius is 50 mm (2 in).

Â Secure the lubrication lines to the machine using nylon ties, clamps or straps provided in the accessory kit.

Â If the feed lines are not primed, prime all lubrication feed lines before connecting them to the lube point (by triggering additional lubrications or via the filler fitting, pos. 4, fig.

17 and 18, page 17).

Â Connect the feed lines directly to the check valves of the metering device and to the Quicklinc fittings of the lube point.

NOTE

6001a02

Push the ends of the feed line firmly into the Quicklinc fitting until it is fully seated in the body of the fitting. The primed feed lines are marked with white lines (fig. 9,

10) to facilitate installation.

Â Cut the pressure plastic tube off at one of the white lines before it is mounted.

Â Then insert the plastic pressure tube into the fitting up to the next white mark.

This will ensure a correct installation of the pressure plastic tube in the threaded tube fitting.

Fig. 10 Vent hole on reservoir

4204a99

Â Fill the reservoir with suitable clean lubricant without air pockets.

WARNING!

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.

1013A94

CAUTION!

Avoid inclusions of air in the lubricant below the follower plate. When filling the reservoir, the follower plate sealing lip overlaps the vent hole (see fig. 10) to ensure that all air pockets can be vented.

Page 10 of 48 2.1A-38006-E05 Form 403013

User Manual


Selection Guide VDC

Pump models

Examples of part numbers

Pump 301 for grease .......................................................... P301

P30100210113

P30162410153

P301 6 2 4 1 0 1 5 3


External, SSV 6, SSV 8

1)

.....................................................


1)

................................................. .

SSV 6 (back) ........................................................................

0

1

3

SSV 8 (bottom) .....................................................................

SSV 12 .................................................................................

4

6

SSV 18 ................................................................................. 9

1)

Note: For external metering device application only use specific SSV metering devices... KNQLS.

SSV Metering Device Position, arrangement of the outlets

Without / external metering device ........................................ 0

Back (vertical order of lines) .................................................

Bottom

2)

1

(horizontal order of lines) ....................................... 2

2)

Note: Do not use QLS 301 with SSV metering device in bottom-mounting position for mobile applications. Do not install the pump in areas exposed to shock (see chapter “Safety Instruc-

Operating Voltage

12 VDC

24 VDC

3)

3)

...............................................................................

...............................................................................

2

4

3)

Note: Standard 12 and 24 VDC pump models for mobile applications can be supplied with 10-meter (30’) cable.

Reservoir

1 liter reservoir with low-level control ..................................... 1

Possible connections

- 1A = 1 connector (square plug), left, power supply ............

- 2A = 2 connectors (square plugs)

1 connector, left, power supply

1 connector, right, fault indication ..............................

- 1A = 1 connector (bayonet plug), left, power supply;

Fault indication ...........................................................

0

1

2

Type of Plug Connector

* Square-type plug, acc. to DIN 43650 type of construction A

(industrial application)

** Bayonet plug, DIN 72585-1, 4-core (mobile application, VDC)

1

5

Electrical Connectors

With socket without cable * ...................................................

With socket and 10 m cable * ...............................................

With socket and 10 m cable ADR * .......................................

With socket and 10 m cable **...............................................

With socket and 6 m cable, ADR ** ......................................

1

5

6

7

8

Control p. c. b.

Terminal board without time control.......................................

Control p.c.b. S3:

NC contact or NO contact (programmable), monitored:

- 1-5 cycles ...........................................................................

0

3

(Accessory kits see ”Technical Data”)

Form 403013 2.1A-38006-E05 Page 11 of 48

User Manual


Selection Guide VAC

Pump models

Examples of part numbers

Pump 301 for grease ........................................................... P301

P30100810113

P30162610113

P301 6 2 6 1 0 1 1 3



1)

.....................................................


1)

................................................. .

SSV 6 (back) ........................................................................

0

1

3

SSV 8 (bottom) .....................................................................

SSV 12 .................................................................................

4

6

SSV 18 ................................................................................. 9

1)

Note: For external metering device application, use the specific metering device SSV ... KNQLS.

SSV Metering Device Position, arrangement of the outlets

External metering device ....................................................... 0

Back (vertical order of the lines) ...........................................

Bottom

2)

1

(horizontal order of the lines) ................................. 2

2)

Note: Do not use QLS 301 with SSV metering device in bottom-mounting position for mobile applications. Do not install pump in areas exposed to shock (see “Safety Instructions“).

Operating Voltage

120 VAC

3)

230 VAC

3)

(only with control p.c.b.) .....................................

(only with control p.c.b.) .....................................

6

8

3)

Note: Standard 120 and 230 VAC pump models for industry are supplied without electrical cable.

Reservoir

1 liter reservoir with low-level control .................................... 1

Possibilities of connection

- 1A = 1 connector (square plug), left, power supply

- 2A = 2 connectors (square plug)

1 connector, left, power supply

1 connector, right, fault indication ...............................

0

1

Type of Plug Connector

* Square-type plug, acc. to DIN 43650 type of construction A 1

Electrical Connectors

With socket, without cable * .................................................. 1

Control p.c.b.

Control p.c.b. S3:

NC or NO contact (programmable), monitored

- 1 cycle with SSV 12, SSV 18

- 1 to 3 cycles with SSV 6, SSV 8 ......................................... 3

(Accessory kits, see ”Technical Data”)

Page 12 of 48 2.1A-38006-E05 Form 403013

User Manual


Electrical Connecting Diagrams

Electrical connection

4273a00

CAUTION!

Before starting, make sure that the electrical supply is off. The device may not be connected or disconnected when the power is on. The protective conductor must always be connected. Take care that this line section is undamaged and conforms to standards and the contacts are safe.

Â Verify the connection and the type of construction of your

QLS.

Â Verify the configuration of your QLS 301:

- Type of voltage (VDC / VAC)

- Low-level control

- Connection (square-type/ bayonet plug)

- Metering device (internal/ external cycle switch)

Â Connect the electrical wires according to the following electrical connecting diagrams (page 13 to 16).

Operation with bayonet plug

4273a00

ATTENTION!

Consider residual ripple of max.

±

5 % to connect pumps with direct current version

(in relation to the operating voltage acc. to

DIN 41755).

ATTENTION!

If the protective-conductor terminal is not connected or interrupted, dangerous touch voltages may occur on the equipment!

6001a02

NOTE

The protection IP6K9K is guaranteed when the socket (X1:, X2:, see fig. 6 ff) is tightened on housing cover with flat packing.

4273a00

Protective measures to be applied for the appropriate operation with bayonet plugs:

"Functional extra-low voltage with safe isolation" /

"Protective Extra-Low Voltage" (PELV)

Standards: EN60204 Part1:1992 / IEC 204-1:1992, modified

DIN VDE 0100 Part 410 / IEC 364-4-41:1992

(see pages 15 and 16)

Alternate current (AC)

with integrated control p.c.b. and attached metering device, alarm contact as normally open or normally closed contact (programmable):

4334a04

Fig. 11 Electrical connecting diagram for alternate current VAC with square-type plug, alarm contact as normally closed contact

Form 403013 2.1A-38006-E05 Page 13 of 48

User Manual


Electrical Connecting Diagrams, continuation

Alternate current (AC)

with integrated control p.c.b. and external metering device, alarm contact as normally open or normally closed contact (programmable):

Fig. 12 Electrical connecting diagram for alternate current VAC with square-type plug, alarm contact as normally closed contact

4335b02

Page 14 of 48 2.1A-38006-E05 Form 403013

User Manual



Direct current (DC), square-type plug


4337a02

Fig. 13 Electrical connecting diagram for direct current VDC with square-type plug, alarm contact as normally closed contact

Direct current (DC), square-type plug


Fig. 14 Electrical connecting diagram for direct current VDC with square-type plug, alarm contact as normally closed contact

4336a02

Form 403013 2.1A-38006-E05 Page 15 of 48

User Manual



Direct Current (DC), bayonet plug


6298a04

Fig. 15 Electrical connecting diagram for direct current VDC with bayonet plug, alarm contact as normally open contact

Direct Current (DC), bayonet plug


6300a04

Fig. 16 Electrical connecting diagram for direct current VDC with bayonet plug, alarm contact as normally open contact

Page 16 of 48 2.1A-38006-E05 Form 403013

User Manual


Description

4198a99

Fig. 17 QLS 301 with back position of the SSV metering device

1

2

3

4

Proximity switch

Control pin

SSV metering device

Nipple for external manual lubrication (1/8’’)

4199b02

Fig. 18 QLS 301 with bottom position of the SSV metering device

2

3

4

5

The QLS 301 is a complete compact lubrication system for a maximum of 18 lubrication points per operating

cycle.

The pump has three basic configurations:

- SSV metering device back-mounted (see Fig. 19)

- SSV metering device bottom-mounted (see Fig. 20)

- Pump without SSV metering device attached respectively with external metering device KNQLS (see fig. 21)

The pump with bottom-mounted SSV metering device has the capability of using steel tubing as lubrication lines if necessary.

Standard lubrication lines are high-pressure plastic hoses included in the pump installation kit for pumps with attached SSV metering device.

NOTE

The function of the pump is independent of the SSV metering device's mounting position.

6001a02

A signal from the pump timer starts the electric motor and the pumping element starts pumping the lubricant to the

SSV metering device.

When all lubrication points have received lubricant, an internal proximity switch (pos. 1, fig. 19, initiator) turns the motor off, completing one operating cycle.

NOTE

6001a02

If the QLS 301 is not provided with an attached SSV metering device but with an external SSV KNQLS (see Fig. 19, page

18), the proximity switch (of the SSV

KNQLS) switches the motor off.

If the operating cycle is not completed within the maxi-

mum permissible time, the flashing fault indication ‘’ Er ‘’ appears on the display of the membrane keypad (see

Fig. 24, page 20). The QLS 301 does not start automatically anymore.

Max. cycle time of the VDC-version ................ 25 minutes

Max. cycle time of the VAC-version ................ 15 minutes

Manifold

SSV metering device

Nipple for external manual lubrication (1/8’’)

Plug (1/8’’) for

P

R external pressure line external return line

Form 403013 2.1A-38006-E05 Page 17 of 48

User Manual


Description, continuation

An externally connected lubricant metering device SSV

KN QLS is equipped with the same proximity switch as the normal QLS 301.

The proximity switch is provided with a connecting cable of 2 m lengths and a connecting plug that must be connected to the socket of the QLS 301.

The socket is integrated in the housing instead of the proximity switch and is connected to the control p.c.b.

NOTE

The function of the QLS 301 is independent of the mounting position of the proximity switch.

6001a02

There are available the following externally connectable metering devices SSV KN QLS:

- SSV 6 KN QLS 619-28945-1

- SSV 8 KN QLS 619-28946-1

- SSV 10 KN QLS

- SSV 12 KN QLS

- SSV 14 KN QLS

- SSV 16 KN QLS

- SSV 18 KN QLS

619-28949-1

619-28950-1

619-28951-1

619-28952-1

619-28953-1

4199b02kopie

Fig. 19 QLS 301 without mounted SSV metering device with connection for external SSV metering device KN QLS

1

2

3

4

P

R

Connecting block

Closure plug

Nipple for emergency lubrication, R 1/8’

Connecting socket for SSV KN QLS

For feed line to external SSV KN QLS

Relief line connection

Page 18 of 48 2.1A-38006-E05 Form 403013

User Manual


Operation

Pump

4205a99

1

2

3

4

The QLS 301 operates according to operating cycles

(pause and lubricating times).

The pause time begins the cycle, and then the lubricating time occurs.

A division of the lube points (option) via sub-metering devices and one main metering device (SSV 6, SSV 8) is possible only up to max. 18 points per operating cycle.

In this case, set the number of cycles of the main metering device according to the number of lube points or the lubricant need to 1, 2, 3 or max. 5 cycles; see P3 on page

27.

Low-level control

Proximity switch

Keypad with display

Control unit

6 SSV 6, 8, 12, 18

Fig. 20 QLS 301, schematic

Pressure Relief Valve

Fig. 21 Pressure relief valve (cartridge) in housing

Pump Display Window

4304a00

The QLS 301 is protected with a pressure relief valve

(cartridge).

The pressure relief valve limits the pressure build-up in the QLS 301. It opens at an overpressure of 205 bar

(3000 psi).

If the pressure relief valve is actuated, this indicates that the system is malfunctioning. The lubricant flows back into the reservoir (hardly visible from outside).

When the monitoring time of 15 minutes (VAC version) respectively 25 minutes (VDC version) has elapsed, the pump switches off. On the display of the membrane keypad appears the flashing fault indication * Er *, see display mode below Setting and Operation of the QLS.

When switching the pump on, the segment in the display window is lit (pause time starts).

4208a04

Fig. 22 Green segment display, pause time

4209a99

Fig. 23 Green rotating display, lubricating time

Pump ”running” is indicated on the display by a rotating light movement of the green display (lubricating time).

If the voltage supply is interrupted during the lubricating time, the times already expired are stored. When the power supply is switched on again, the lubricating time continues operating from the point where it had been interrupted.

Form 403013 2.1A-38006-E05 Page 19 of 48

User Manual


Operation, continuation

Monitoring time/ malfunction

Fig. 24 Display of a fault indication

4210a99

4228a02

Fig. 25 Membrane keypad with fault indication and operator keys

1

2

3

Display window

Operator key

– operating mode: trigger additional lubrication

– programming mode: setting of times and metering

device cycles – terminate programming

Operator key

– display mode: acknowledge receipt of flashing

functional fault

- Operating mode: display of the set pause time and

residual pause time

– programming mode: change to the different

programming levels

If the proximity switch (pos. 1, fig. 17, page 17) does not give any feedback after the pause time has elapsed or after triggering additional operating cycles within 15 min-

utes (AC monitoring time) or 25 minutes (DC monitoring time), the pump switches off immediately. The flashing fault indication * Er * (Error) appears on the display.

IMPORTANT

If a malfunction is present, the pump does not switch on automatically any longer.

6001a02

Â In this case, switch on the pump by pressing the button for additional operating cycle (pos. 2, fig. 31).

Â The fault can be confirmed (see pos. 3, Fig. 25). However, this is not obligatory.

IMPORTANT

When confirming a fault indication, the flashing light changes into a permanent light or a signal horn can be temporarily switched off.

6001a02

When a malfunction is present, it can be cancelled only by initiating an additional operating cycle and if a proper operating cycle has been executed afterward.

If the fault is still present after an additional operating cycle has been initiated, the fault indication ”Er” is displayed again.

The monitoring time starts in parallel to the lubricating time. It is firmly adjusted and amounts to 15 respectively

25 minutes.

If the voltage supply is interrupted during the monitoring time (lubricating time), the monitoring time starts from the beginning after the pump is switched on again.

Low-level indication

Low-level indication

6262b04 6263b04

Fig. 26 Announcement of a low-level indication

6264b04

* L6 *, … * L1 * announces a low-level indication.

Right at the end appears the flashing display * LL * to indicate an unconfirmed low-level indication (see page 21,

Fig. 27).

Page 20 of 48 2.1A-38006-E05 Form 403013

User Manual



Low-level indication, continuation

Fig. 27 Display of a low-level indication

4211a99

1

2

3

The follower plate (3) (Fig. 28) of the reservoir moves the pin (pos. 2) with the solenoid (pos. 1) ahead of the sensor on the printed circuit board and initiates the low-level signal.

In this case, the pump is not switched off immediately.

The current operating cycle is completed. Upon expiration of the pause time, the pump cannot be started again automatically. The flashing display ”LL” appears, see Fig.

27.

Â Fill reservoir.

As soon as the lubricant reservoir is filled up, the ”LL” display is cancelled. The operating cycle resumes.

Solenoid

Pin

Follower plate

Fig. 28 Parts of the low-level indication

Operator keys of the keypad

Operator keys of the keypad in the operating mode

4222a99

Fig. 29 Pushbutton for additional operating cycle

4229a99

Malfunction/low-level indication

If both indications (fig. 24 and 27) occur at the same time, then both displays * Er * and * LL* will flash.

Additional operating cycle

Â is triggered via the button (Fig. 30). Press the button for

2 seconds.

Â can be initiated at any time, provided that the power supply is applied.

If a fault signal (malfunction) is present, it will be cancelled as soon as the system is operating properly, again.

NOTE

6001a02

An existing fault indication (flashing display) can be confirmed before triggering additional operating cycles. However, this

is not obligatory (see Fig. 29).

Operator keys of the keypad in the programming mode

Fig. 30 Key for resetting the pause time

4222a99

Reset of the pause time

Â Setting of the pause time by

- single key activation for one hour/minute

- permanent activation for quick run

Setting of the monitoring relay

Setting of the metering device circulations:

The monitoring relay signalizes a functional fault on an external lamp via the optional connection “X2“ (see connecting diagrams).

In case of the standard setting “normally open contact” the fault is indicated by a lamp with permanent light.

In case of the setting “normally closed contact” the fault is indicated by a lamp gone out.

Form 403013 2.1A-38006-E05 Page 21 of 48

User Manual



Operator keys of the keypad, continuation

Operator keys of the keypad in the programming mode, continuation

Continuation of fig. 30:

4222a99

Key for resetting the pause time

Â For VDC version ……………………………. 1 to 5 cycles

For VAC version

- SSV 6 / SSV 8 ……………………………... 1 to 3 cycles

- SSV 12 / SSV 18 ….……………………….......... 1 cycle

Start settings

Â Set: SP (Start with pause time)

SO (Start with lubricating time)

Â Termination of the programming mode.

Operator keys of the keypad in the display mode

4214a99

Acknowledging receipt of a malfunction

Â By pressing the key (fig. 31) the flashing *Er* changes into a permanent light.

Acknowledging receipt of the low-level indication

Â By pressing the key (fig. 31) the flashing *LL* changes into a permanent light.

Fig. 31 Acknowledging receipt of a flashing fault indication

Operator keys of the keypad in the operating mode

Display of information regarding the set pause time

and residual pause time

Â Press key >2 seconds.

4214a99

Fig. 32 Information regarding the set pause time and residual pause time

Operator keys of the keypad in the programming mode

4214a99

4222a99

Changing to the different programming levels

Â Press keys to access the programming mode.

Â Set parameters.

Â

Â Setting: hours ….……………………………. P1 minutes P2 metering device cycles …………. P3 outlet potential-free contact ….... P4 external display for functional faults of

(NO) or (NC) contacts ................. P5 start with pause time or lubricating time …………………….. P6 termination of programming

4214a99

Fig. 33 Changing to the different programming levels

Monitoring relay

The monitoring relay signals a low-level indication or a malfunction (only in combination with optional connector

X2, see electrical connection diagrams).

In the first case the relay picks up (normally open contact).

In the second case the relay releases (normally closed contact, broken-wire interlock).

The signal is available via a potential-free contact.

The monitoring relay is released upon acknowledgement of the fault.

Page 22 of 48 2.1A-38006-E05 Form 403013

User Manual


Setting and Operation

6001a02

NOTE

The following technical description includes information on the centralized lubrication systems QLS 301 after upgrading them with the following control printed circuit boards:

- for 12/24 VDC … 236-14212-7

- for 120 VAC …… 236-10298-6

- for 230 VAC …… 236-10298-1

Factory Settings

Programming steps Factory setting Description

6 h

6 hours Pause time

4215a99

0 min

4217a99

4218a99

6252b04

6255b04

1 cycle no

– –

SP

Page

7

0 minutes Pause time

Operating cycles:

1 cycle (metering device cycle)

7

8

Signal output of the fault relay: no (normally open) Signalizing during the failure, 8

Differentiation fault indication (ER) / low-Level control (LL):

– – Permanent signal (no differentiation

between ER and LL)

Start phase:

SP Start with pause time

9

10

4299a00

Tab. 1 Programming steps P1 to P6

Operator Keys

Fig. 34

4222a99

Key for modifying the parameters in the programming step

Fig. 35

4214a99

Key for switching to the next programming step

Form 403013 2.1A-38006-E05 Page 23 of 48

User Manual


Setting and Operation, continuation

Three possible modes of operation and settings can be selected on the keypad.

Display mode

Programming mode (page 26 ff)

Operating mode (page 30 ff)

Display Mode

In the display mode the user receives information on functions and malfunctions of the QLS 301.

As soon as voltage is applied to the pump, the keypad is automatically in display mode. The segment is illuminated on the display.

Normally, the display is dark. Only the functions (segment, rotating segment display) or malfunctions (* Er *, * LL *) are displayed.

4206a04

Display press

A test display is made when the voltage is applied, all segments and decimal points are illuminated for 2 seconds.

NOTE

2 sec.

4207a99

6001a02

If *EP* is displayed after the display test, there is a malfunction of the operating keys (see page 20).

If *EE* is displayed, this indicates an electromagnetic interference. In this case, individually set times are set back to the factory setting and must be programmed newly

4227a99 6574b05

In the display mode during the pause time there appears the right segment display (On). It is to display the readiness for operation (voltage supply). As soon as another message is displayed, the segment turns off.

4208a04

The lubricating time is displayed as a rotating segment.

4209a99

Fig. 36 Display Mode (continuation next page)

Page 24 of 48 2.1A-38006-E05 Form 403013

User Manual



Display Mode, continuation

Display press

* Er * is shown to indicate a malfunction.

4210a99

6262b04 6263b04 6264b04

In the display mode, a low level is announced by an intermittent display of * L8 *, * L7 *, * L6 *, … * L1 *.

Finally appears the intermittent display * LL * for a lowlevel indication that had not been confirmed.

4210a99

Fig. 36 Display Mode

4214a99

< 2 sec.

To acknowledge malfunctions

The flashing display is changed into a continuous light by pressing the button (acknowledging). To acknowledge, press the button only briefly (< 2 sec.).

Messages which have been acknowledged but have not yet been remedied flash again after the pump is switched off and on again.

Form 403013 2.1A-38006-E05 Page 25 of 48

User Manual



Programming Mode

Display

4215a99

4222a99

press

4214a99

> 4 sec.

Setting Pause Time P1 and P2

Â To access the programming mode, press both buttons at the same time > 4 seconds, so that “P1” appears in the display.

Programming options: Pause time:

Min. pause time DC 4 minutes

Min. pause time AC 20 minutes

Max. pause time DC/AC 59 hours 59 minutes

P1: Setting hours

When releasing the two buttons, the currently set value appears (here the factory-set value: 6 hours).

The field “hour“ is indicated by a decimal point on the right-

hand side.

4281a00

4220a99

4217a99

6270b04

4222a99

4214a99

4222a99

4220a99

Fig. 37 Programming Mode (continuation next page)

Â Press button.

Â Settings are made in one direction: 0, 1, 2, 3,....59 h

Button pressed once …............. increases by 1 hour

Button pressed continuously ........... quick sequence

P2: Setting minutes

Â Press button, so that “P2“ appears in the display.

When releasing the button, the currently set value appears

(her the factory-set value: 0 minutes).

The field “minute“ is indicated by a decimal point on the left-

hand side.

Â Press button.

Â Settings are made in one direction: 0, 1, 2, 3, 4, .... 59 min

Button pressed once ….......... increases by 1 minute

Button pressed continuously ........... quick sequence

6001a02

NOTE

The minimum pause time is 4 respectively

20 minutes. For settings < 4 respectively

< 20 minutes (without input of hours) there automatically appears “. 04“ respectively

“. 20“ in the display provided the programming sequence has been carried out completely.

Page 26 of 48 2.1A-38006-E05 Form 403013

User Manual



Programming Mode, continuation

P3: Setting number of cycles

If lube points are divided via sub-metering devices (SSV 6) and a main metering device (SSV 6, SSV 8), never exceed a

maximum of 18 (24) lube points.

4218a99

4219a04

4219a99

4214a99

4222a99

IMPORTANT

Settings are only possible in connection with progressive metering device SSV 6 or SSV 8 KNQLS (connected as a main metering device) and a jumper attached at the p.c.b


Max. cycle time VDC …………………………………… 1 to 5

Max. cycle time VAC …………………………………… 1 to 3

When releasing the button, the currently set value appears

(here the factory-set value: 1 cycle)

Â Press button.

Â Settings are made in one direction: 1, 2, 3, 4, 5

6001a02

NOTE

For the VDC version all metering device cycle numbers are possible with SSV 6,

SSV 8, SSV 12 and SSV 18.

For the VAC version depending on the type of SSV metering device the following cycle numbers are possible:

- with SSV 6 and SSV 8 .…………... 1 to 3

- with SSV 12 and SSV 18 ......……..….. 1

6252b04

6254b04

4214a99

4222a99

6253b04


P4: Programming of the output signal on the monitoring relay for external fault indication (external fault contact)


When releasing the button, the currently set value appears in the display (here the factory-set value “no“, normally open contact).

Â Press button.

The external fault contact is modified by programming it as an “nc“ normally closed contact.

Form 403013 2.1A-38006-E05 Page 27 of 48

User Manual




P5: Program external display for empty reservoir or fault indications


4214a99

6255b04

6256b04 factory setting

When releasing the button, the display symbol “- -“ for permanent signal appears in the display.

NOTE

In this setting, a differentiation between low-level indication and fault indication is not possible.

6001a02

6257b04

4222a99

The output signal on the monitoring relay for the external fault indication “P4“ is set as a normally open contact (no) (see page 30).

Â Press key to change the external signal into an intermittent signal.

Then low-level indications appear as intermittent signals and malfunctions as permanent signals (On).

On

Off intermittent signal

On

Off

Permanent signal

6258b04

4222a99

On

Off

On

Off intermittent signal Permanent signal


The output signal on the monitoring relay for the external fault indication “P4“ is set as a normally closed contact (nc) (see page 30).

Â Press key to change the external signal into an intermittent signal.

Then low-level indications appear as intermittent signals and malfunctions as permanent signals (Off).

Page 28 of 48 2.1A-38006-E05 Form 403013

User Manual




4299a00

6259b04

4214a99

P6: Program start phase


The pump is set as a standard with starting pause time SP

(Start Pause time).

Â Press button.

The pump then starts after each switching on with the lubricating time SO (Start Operation). After the first lubricating time the preset pause time is valid.

6260b04

4222a99

4221a99

4214a99

4222a99

Completing the programming

Â Press button. „ P -“ is displayed.

IMPORTANT

6001a02

In order to avoid a wrong program, make sure to always carry out the programming order completely, i. e. setting of P1

(hours), P2 (minutes), P3 (number of cycles), P4 (external contact), P5 (external display), P6 (start phase) and P- (Programming end).

Press this key (additional lubrication) to complete the programming and to save the entered parameters.

6001a02

NOTE

If the button “additional lubrication” is not pressed within 30 seconds, the changed parameters are not saved and the previous programming remains valid.

IMPORTANT

After completion of the programming, check the parameter settings in the operating mode once again (see pages 33 ff).

4208a99

Fig. 37 Programming Mode

Form 403013 2.1A-38006-E05 Page 29 of 48

User Manual



Operating Mode

Display press

IMPORTANT

The operating mode is accessible only during the pause time, and cannot be operated during the running time (pump lubricating time).

6001a02

Precondition: When the voltage supply is applied, the segment (On) is lit.

4208a04

Operating option: Initiating an additional operating cycle

Â Press the button (> 2 sec.). The elapsed pause time is reset. The lubricating time starts. A rotating segment is visible on the display during the whole lubricating time.

> 2 sec.

4209a99 4222a99

Operating option: Calling up of set parameters and data determined

4208a04

4123a99

4216a99

4220a99

4214a99 after two sec. after two sec. after two sec.

Â Press the button.

PP (set pause time)

NOTE

6001a02

The following display sequence is shown

once and is cancelled after 40 seconds.

The change of display occurs every two seconds. Example:

PP

rP

= 12h 30 min

= 5h 10 min

12 . (hours)

. 30 (minutes)

rP (remaining pause time)

4224a99

Fig. 38 Operating Mode (continuation next page)

Page 30 of 48 2.1A-38006-E05 Form 403013

User Manual



Operating Mode, continuation

after two sec.

5 . (hours)

4225a99 after two sec.







4226a99

Fig. 38 Operating Mode (continuation next page)

. 10 (minutes)

AC number of the automatically triggered operating cycles, countable up to 9999 cycles.

Then counting starts from the beginning again.

Example 0625 cycles:

06. Display for thousands and hundreds

06 as 600

.25 Display for tens and ones

UC Number of the manually triggered

(by the user) additional operating cycles, countable up to 9999 cycles.

Then counting starts from the beginning again.

Example 0110 cycles:

01. Display for thousands and hundreds

01 as 100

.10 Display for tens and ones

Form 403013 2.1A-38006-E05 Page 31 of 48

User Manual



Operating Mode, continuation

after two sec.

4218a99

4219a99

6252b04

6253b04

6255b04

6256b04

4299a00

6260b04 after two sec. after two sec. after two sec. after two sec. after two sec. after two sec. after two sec. after approx. 40 sec.

P3: Number of metering device cycles

Display of the metering device cycles

P4: Programming of the output signal

Display of the output signal “normally closed“ (nc) or “normally open“ (no)

P5: Differentiation between low-level indication and fault indication (only external indication)

Differentiation inactive

P6: Programming of the start phase

Display of the start phase with “start lubricating time“ (SO) or

“start pause time“ (SP)

Termination of the operating mode

4208a04

Fig. 38 Operating Mode

Page 32 of 48 2.1A-38006-E05 Form 403013

User Manual


Maintenance, Repair and Tests

Maintenance

Maintenance is essentially limited to refilling the reservoir with clean lubricant as necessary. However, check regularly whether the lubricant is being dispensed to all the lubrication points.

Also check the feed lines for damage and replace them, if necessary.

4273a00

CAUTION!

Turn off the voltage supply for pumps

120 VAC and 230 VAC before servicing the pump.

6001a02

NOTE

Whenever work is performed on the centralized lubrication system, special attention should be paid to cleanness.

Dirt will cause failure of the system.

IMPORTANT

To clean the system use petroleum spirit or petroleum. Do not use Tri, Per or similar solvents or polar or organic solvents such as alcohol, methanol, acetone, etc.

To fill reservoir

4231a99

Fig. 39 Filling nipple for filling reservoir

1 Filling nipple

3 Follower plate

Filling of the empty reservoir

Make sure that all air has been expelled from under the follower plate after refilling the empty reservoir.

The follower plate seal should contact the hole located on the top of the reservoir. Small amount of grease should be refilled to ensure expelling of air from under the follower plate.

Fill the reservoir up to the ”Max.” mark via the filling nipple, see fig. 38.

IMPORTANT

6001a02

The grease must be free from impurities and must not be liable to change its consistency over the course of time.

NOTE

If the reservoir has been completely emptied, the pump may require priming and a longer running time to reach the full lubricant output. Therefore, trigger additional operating cycles manually.

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.

Form 403013 2.1A-38006-E05 Page 33 of 48

User Manual


Maintenance, Repair and Tests, continuation

Repair

For repair work on the QLS 301 use only original Lincoln spare parts.

CAUTION!

Switch off the voltage supply for pumps 120 VAC and 230 VAC before servicing the pump.

4273a00

CAUTION!

By operating the drive motor without the reservoir installed, there is a risk of

injury by the eccentric gear.

Never use the lubrication system QLS

301 without installing the reservoir!

1013A94

Functional Test

Â Press pushbutton > 2 sec. to trigger an operating cycle.

4222a99

Fig. 40 Pushbutton for additional operating cycle

Page 34 of 48 2.1A-38006-E05 Form 403013

User Manual


Pump of the QLS 301 system

Troubleshooting

The green rotating display indicates that the pump operates properly.

4209a99

Fig. 41 Green rotating segment, lubricating time

Fault: Pump motor doesn’t run

Cause: Remedy:

Power supply interrupted. Green decimal point On/h on display is not lit.

Warning!

Disconnect the power supply before starting any maintenance or repair works.

Power supply from printed circuit board to motor interrupted. Electric motor defective.

4273a00

Â Check the voltage supply to the pump/fuses. If necessary, eliminate the fault or replace the fuses.

Â Check the feedline from the fuses to the plug of the pump and then to the printed circuit board.

Â Trigger an additional operating cycle. Check voltage supply from the printed circuit board to the motor.

Â Replace printed circuit board.

Â Replace housing with keypad.

Printed circuit board defective

Keypad or button is defective. ”EP” display at the keypad flashes.

Fault: Pump does not deliver lubricant

Cause: Remedy:

Reservoir is almost empty. ”LL” display at the keypad is flashing.

Pump lost prime and ”Er” display at the keypad is flashing.

Â Fill up the reservoir with clean grease. Let the pump run

(initiate an additional operating cycle) until lubricant shows at all lube points.

NOte

Air pockets in lubricant.

Improper lubricant has been used.

Suction hole of pump element clogged.

Pump piston is worn.

Check valve in pump element defective or clogged.

6001a02

Dependent on the ambient temperature and/or sort of lubricant output. Therefore, trigger several additional operating cycles.

Â Trigger an additional operating cycle. Lubricant must dispense without air bubbles.

Â Change the lubricant.

Â Remove pump element. Check suction hole for foreign particles. If there are any, remove them.

Â Replace pump element.

Â Replace pump element.

Form 403013 2.1A-38006-E05 Page 35 of 48

User Manual


Troubleshooting, continuation

Fault: Pump either does not switch off at all or only after the monitoring time of 15 min.

Cause: Remedy:

Proximity switch is not dampened, i.e. the control pin does not move within the switching range of the initiator, or the distance between the control pin and the initiator surface is more than 0.5 mm (0.02 in.).

Â Trigger additional lubrication. Check whether the control pin moves centrically over the switching surface of the initiator. In case the adjustments do not correspond to the indications, the fixing position of the metering device has to be corrected.

Â Check the distance.

- Between the control pin and the switching surface of the initiator (max. 0.5 mm; 0.02 in.)

In case the adjustments do not correspond to the indications, the fixing position of the proximity switch has to be corrected.

- Distances between the switching surface of the initiator and the upper edge of the fixing nut:

When the metering device is mounted at the back: 16+ /

–0.2 mm (0.62+/-0.08 in.)

When the metering device is mounted at the bottom:

12.7 +/-0.1 mm (0.5 +/-0.004 in.).

Â Tightening torque of the nut: 1.5 NM (1.10 ft-lb.).

Fault: Pump runs continuously

Cause: Remedy:

Programming of pause time in step P1 was set to‘’00”.

Programming of further steps P2, P3, P4, P5, P6 and P- was not carried out.

Pump starts running immediately. The proximity switch switches off the cycle for two minutes. Then, pump runs continuously.

Â Switch off pump (power supply) by removing left-hand side socket from plug.

Â Press both buttons of keypad:

4222a99 4214a99

> 5 sec.

Â Switch on pump (power supply) by replugging left-hand side socket.

Â Release both pushbuttons after approx. 5 seconds.

Â The factory-set pause time of 6 hours is automatically reset.

Â Afterwards new setting of pause time is possible.

Fault: Fault indication * EE *

Cause: Remedy:

Electromagnetic interferences have modified the customer’s time setting. All values have been set back to the factory setting.

Â Eliminate electromagnetic interferences.

Â Repeat individual programming (see as of page 26).

Page 36 of 48 2.1A-38006-E05 Form 403013

User Manual



SSV metering device

Fault: Blockage in the downstream progressive system

Cause: Remedy:

Bearings, lines or metering device clogged Determine the cause of the blockage as described in the following example and eliminate it.

Mounting position of metering device: bottom

- In the case of metering devices SSV 8,12 and 18, the outlets 1 and/or 2 are closed.

Â Let the pump run (refer to ”trigger additional operating cycles”).

Mounting position of metering device: back

- In the case of metering devices SSV 6, 12 and SSV

18, outlet 1 is closed and outlet 2 is connected to a lube point.

The fault can be identified as follows: a) Fault indication ”Er” flashing on the keypad display. b) The indicator pin at the metering device piston does

not move.

Â Disconnect all feed lines (pos. D) of the metering device one after the other. If grease shows under pressure the blockage is located in the line of outlet 3 or in the connected bearing point.

Â Pump through the blocked line or bearing point using a hand pump.

NOTE

6001a02

To check the individual outlets, leave all outlets disconnected for a while, since only one piston stroke is executed with each motor revolution. Several strokes are required for a full cycle of all metering devices.

Â Check pressure relief valve (fig. 21, page 19). Replace it, if necessary.

Fig. 43 Example of a QLS 301

B pump

C

D

R

SSV 12 metering device feed lines return line

4232b02

Form 403013 2.1A-38006-E05 Page 37 of 48

User Manual



Fault: Blockage in the downstream progressive system, continuation

Cause: Remedy:

Metering device is blocked

Fault: Differing lubricant amounts at the lubrication point

Â Replace the metering device or clean it as follows:

- Remove all threaded tube fittings.

- Unscrew the piston closure plugs.

- Remove the piston, if possible, with a soft mandrel

(smaller than ø 6 mm, 0.24 in).

IMPORTANT

6001a02

The pistons are individually fit in the bores of the metering device. After removing the pistons, mark them in order to reinstall them in the right direction and position. They may not be interchanged.

- Thoroughly clean the metering device body in a greasedissolving detergent and dry it with compressed air.

- Clean through the material passages (ø 1.5 mm, 0.59 in) at the thread ends of the piston bores using a pin.

- Clean the metering device once more and dry it thoroughly.

- Reassemble the metering device.

Cause: Remedy:

Lubricant metering not correct.

Setting of the pause time incorrect.

Â Check the lubricant metering acc. to the lubrication chart.

Â Check time setting.

Page 38 of 48 2.1A-38006-E05 Form 403013

User Manual


Technical Data

QLS 301, GENERAL

Operating temperature........ -25° C to 70° C (-10° F to 160° F)

Maximum operating pressure of pump model without metering device...... 205 bar (3,000 psig)

Number of outlets................................................... 6, 8, 12, 18

Output per outlet and cycle ............................. approx. 0.2 cm²

Reservoir capacity ...............................................................1 l

Lubricant .................................................. up to NLGI 2 grease

Weight (average) ......................................... 5.7 kg. (12.5 lbs.)

Protection................................. IP6K 9K acc. to DIN 40050 T9

Reverse polarity protection:

The operating voltage inlets are protected against reverse polarity.

ELECTRICAL DATA AC (ALTERNATE CURRENT)

Operating voltage.............................. 120 VAC/60 Hz +/- 10 %

Operating current .............................................................1,0 A

Operating voltage........................ 230 VAC; 50/60 Hz +/- 10 %

Operating current .............................................................0.5 A

ELECTRICAL DATA DC (DIRECT CURRENT)

Operating voltage...................................... 12 V, - 20%/+ 30 %

Operating current .............................................................2,0 A

Operating voltage...................................... 24 V, - 20%/+ 30 %

Operating current ............................................................1.0 A

Residual ripple in relation to the operating voltage ...................... ± 5% acc. to DIN41755

NOTE

The pump motor is suitable for intermittent operation only.

6001a02

In addition to the EMV directive, DC systems also comply with the following guidelines and standards:

- vehicle guideline 95/245/EC

- EMV regulation for on-road vehicles acc. EN 40839 parts 1, 3 and 4

TIME SETTING

Range of pause time ................................ increment 1 minute

- VDC ................................................... 4 minutes to 60 hours

- VAC ................................................. 20 minutes to 60 hours

Factory setting

Pause time .......................................................... 6 hours/cycle

Numbers of operating cycles

- VDC ................................................................. 1 to 5 cycles

- VAC SSV 6 / SSV 8 .......................................... 1 to 3 cycles

SSV 12 / SSV 18 ............................................... 1 cycle

Timer memory................................ indefinite over EEPROM

RELAY FOR MALFUNCTION AC (OPTION)

Potential-free outlet for malfunction/low-level option

Switching voltage.............................. max. 230 VAC/ 125 VDC

Switching current ....................................... max. (resistive) 2 A

Switching capacity ......................................max. 100 VA/80 W

RELAY FOR MALFUNCTION DC (OPTION)

Potential-free outlet for malfunction/low level option

Switching voltage....................................... max. 48 VAC/ VDC

Switching current ....................................... max. (resistive) 2 A

Switching capacity ......................................max. 100 VA/80 W

NOTE

All data depends on operating voltage, ambient temperature and max. operating pressure.

6001a02

LINES

Plastic tube (ø 6x1,5 mm;1/4 in.)

Min. bending radius . .............................................50 cm (2 in.)

Bursting pressure at 20° C ( 70°F) .............................approx. 210 bar (3050 psi )

Min. temperature ................................................-25° C (-10°F)

TIGHTENING TORQUES

Pump

Electric motor to housing..................................3 NM (2.5 lb.-ft)

Pump element in housing............................25 NM ( 19.0 lb.-ft)

Metering device, accessories

Closure plug (piston) in metering device .....18 NM (13.5 lb.-ft)

Closure plug (outlets) in metering device ....15 NM (11.0 lb.-ft)

Outlet fitting in metering device

- screw-type ..............................................17 NM (12.5 lb.-ft)

- push-in type..............................................12 NM (9.0 lb.-ft)

Compression nut onto outlet fitting, screw-type:

- plastic tube ...............................................10 NM (7.5 lb.-ft)

- steel tube..................................................11 NM (8.0 lb.-ft)

Indicator pin in metering device ...................18 NM (13.5 lb.-ft)

Mounting of the metering device....................10 NM (8.0 lb.-ft)

ACCESSORY KITS:

Inch-Size Kits:

SSV 6/8 part no. 550-36971-1

SSV 12 part no. 550-36971-2

SSV 18 part no. 550-36971-3

Metric Size Kits:

SSV 6/8 part no. 550-36970-1***

SSV 12 part no. 550-36970-2***

SSV 18 part no. 550-36970-3***

***

Lube fittings must be ordered separately

Form 403013 2.1A-38006-E05 Page 39 of 48

User Manual


Pump and SSV metering devices

Dimensions

Fig. 44 Dimension of QLS 301

4233a99

Fig. 45 Dimensions of back-mounted SSV metering device

Number of outlets Dimension A in mm

4234b04

Number of outlets Dimension A in mm

2012b95

Fig. 46 Dimension of bottom-mounted SSV metering device

Page 40 of 48 2.1A-38006-E05 Form 403013

User Manual


Service Parts

Version with bayonet plug

(VDC application only)

6302b04

Fig. 47 QLS 301 housing with bottom-mounted SSV metering device and bayonet plug (replacement of pos. 11, Fig. 49)

6303b04

Fig. 48 QLS 301 housing with back-mounted SSV metering device and bayonet plug (replacement of pos. 11, Fig. 50)

Parts list for bottom-mounted and back-mounted SSV lubricant metering devices with bayonet plug

Pos. Description Kit Single

Part

Qty Part No.

11 Housing cover for

VDC, plug 1A1

11.1 Socket with 6 m cable for bayonet plug or

Socket with 6 m cable for bayonet plug ADR

11.2 Bayonet plug x 1 664-34045-2 x 1 550-36980-1

Tab. 2 Parts list, QLS 301 with bayonet plug to table 3 and 4

(instead of square-type plug, pages 43 and 45)

Form 403013 2.1A-38006-E05 Page 41 of 48

User Manual


Service Parts, continuation

QLS 301 with bottom-mounted SSV metering device and square-type plug

Fig. 49 QLS 301 with bottom-mounted SSV metering device and square-type plug

Page 42 of 48 2.1A-38006-E05

4193b02

Form 403013

User Manual



Parts list for bottom-mounted SSV metering device and square-type plug

Pos. Description Kit Single part

Qty Part No. Pos. Description Kit Single part

Qty Part No.

1 Reservoir

2 Spring

DA 28x1,6x106 x 1 550-36979-2

13 p.c.b. for 1-5 cycles x 1 550-36980-1 x 1 550-36983-7

4 Intermediate x 1 550-36979-3

1 450-24749-1 p.c.b. for 1 cycle x 1 550-34199-1

6 Shaft

7 Pressure relief valve, cartridge

11.3 Flat packing

11.4 Appliance plug 2 , for remote control, VDC

Appliance plug 2 , for remote control, VAC

11.5 Appliance plug 1, for power supply, VDC

Appliance plug 1, for power supply, VAC

11.6 Socket 1 with 10 m cable, for power supply

11.7 Screw with washer assy. x 1 550-36979-4 x 1 550-36979-1 x 2 236-13294-3 p.c.b. for 3 cycles

ø 6 mm assy. x 1 control

15 Motor, 12 VDC pump element

10 Housing with low level control

With square-type plug (pos. 11, fig. 49, page 42):

Motor, 24 VDC

Motor, 120 VAC

11 Housing cover with low level control and VDC, plug 1A1 x 1 550-34179-3

Motor, 230 VAC

15.1 Motor connection

VDC

15.2 Motor connection

VAC or VDC, plug 2A1

Housing cover with low level control x and VAC, plug 1A1 x or VAC, plug 2A1

11.1 Socket 2 with 10 m cable, for remote control x

1 550-36984-2

1 550-36984-3

1 550-36984-4

16 Hydraulic lube fitting,

ST AR 1/8

17 Adapter M 22x1,5 (a) x G 1/8 in.(i)

18 O-Ring ø 5 x1,

5 mm

11.2 Socket, black

GMD-3011

20 Sealing ring aluminum

21 Manifold

22 Connecting

23 Hydraulic lube fitting,

ST AR 1/8

SSV 8 - K

SSV 12 - K

SSV 18 - K

25 Piston plug with sealing for control pin

Sealing kit for

QLS 301 x 1 550-34199-3 x 1 550-34199-2 x 1 550-34199-4 x x x x x x x x x x x

1 550-36979-9

1

1

1

1 550-36982-4

1 226-13777-2

1 550-36979-6

1 550-36979-7

1

1

1

550-36982-1

550-36982-2

550-36982-3

619-37586-1

619-37587-1

619-37588-1

Form 403013 2.1A-38006-E05 Page 43 of 48

User Manual



QLS 301 with back-mounted SSV metering device and square-type plug

Fig. 50 QLS 301 with back-mounted SSV metering device and square-type plug

Page 44 of 48 2.1A-38006-E05

4194b02

Form 403013

User Manual



Parts List for back-mounted SSV metering device and square-type plug

Pos. Description Kit Single

Part

Qty Part No. Pos. Description Kit Single

Part

Qty Part No.

1 Reservoir

2 Spring

DA 28x1,6x106 x 1 550-36979-2 x 1 550-36979-3

4 Intermediate bottom

5 Eccentric x 1 550-36979-4

6 Shaft x 1 550-36979-1

11.6 Socket 1 with 10 m cable, for power supply assy.

13 p.c.b. for 1-5 cycles valve, cartridge p.c.b. for 1 cycle assy. ø 6 mm pump element

10 Housing with lowlevel control

With square-type plug (pos. 11, fig. 50, page 44):

11 Housing cover with low level control and VDC, plug 1A1 or VDC, plug 2A1 x

Housing cover with low level control x and VAC, plug 1A1 x or VAC, plug 2A1 x

11.1 Socket 2 with 10 m cable, for remote control

1 550-34179-3

1 550-36984-2

1

1

550-36984-3

550-36984-4

GMD-3011 x 2 236-13294-3 p.c.b. for 3 cycles

14 Low-level 1 550-36979-9

15 Motor, 12 VDC x 1 550-36982-1

Motor, 24 VDC

Motor, 120 VAC

Motor, 230 VAC x x x

1

1

1

550-36982-2

550-36982-3

550-36982-4

VDC

VAC fitting, ST AR 1/8

17 Adapter M 22x1,5

(a) x G 1/8 in.(i)

18 O-Ring ø 5 x1,

5 mm

11.4 Appliance plug 2, for remote control,

VDC

Appliance plug 2, for remote control,

VAC

11.5 Appliance plug 1, for power supply,

VDC

Appliance plug 1, for power supply,

VAC device

SSV 6 - K

SSV 12 - K

SSV 18 - K fitting, ST AR 1/8

21 Piston plug with sealing for control pin

Sealing kit for

QLS 301 x x x

1 619-37589-1

1 619-37590-1

1 619-37591-1

Form 403013 2.1A-38006-E05 Page 45 of 48

User Manual


Option for metric fittings

(not included in the accessory kits)

SSV Connecting tube fitting, screw-type and push-in type

4239a99

1

2

3

Ferrule nut

Cutting ring

Valve body with sealing and ferrule

Fig. 51 Screw-type check valve

Connection of the pressure plastic tube or the high-pressure hose

1009a98

A

B

1a

2a

For high-pressure hose (ø 4.1 x 2.3 mm) use check valve

A, fig. 52, with reinforced collets 1a and smooth flange

(part no. 226-14091-4)

For pressure plastic tube (ø 6 x 1.5 mm) use check valve

B, fig. 52, with standard collets 2a and knurled flange (part no. 226-14091-2)

Check valve with reinforced collets

Check valve with standard collets

Smooth flange

Knurled flange

Fig. 52 Different types of check valves

NOTE

6001a02

On construction machines or agricultural machines use high-pressure hoses as feed lines. In such cases, the check valves of the sub-metering devices must have a reinforced collets and a smooth flange.

6001a02

IMPORTANT

Connect only high-pressure hoses

(ø 4.1 x 2.3 mm) with threaded sleeve and hose stud to the check valves with reinforced collets.

4156a98

Fig. 53 Check valve with reinforced collets and high-pressure hose

Page 46 of 48 2.1A-38006-E05 Form 403013

User Manual


Option for metric fittings

(not included in the accessory kits), continuation

Mounting of the threaded sleeves and hose studs onto the high-pressure hose

Screw threaded sleeve (1, fig. 54) counterclockwise onto the high-pressure hose (2) until the illustrated dimension of 11mm is reached. Then screw the hose stud (3) into the threaded sleeve (1).

IMPORTANT

Oil parts 1 and 3 well before screwing them together.

6001a02

1028a96

Fig. 54 Pre-assembly of the threaded sleeves and hose studs onto the main line

2

3

Main line

Hose stud

EC Declaration of Conformity as defined by Machinery Directive

98/37/EC, Annex II A

This is to declare that the design of the

QLS 301 lubrication system

in the version supplied by us, complies with the provisions of the directive 98/37/EC – including all modifications of this directive valid at the time of the declaration.

Applied harmonized standards in particular:

EN 12100-1

Safety of machinery part 1

EN 12100-2

Safety of machinery part 2

EN 809

Pumps and pump units for liquids

Safety requirements

Part 1: General requirements

EC Declaration of Conformity according

EMC Directive 2004/108/EC

We declare that the model of the

QLS 301 lubrication system

in the version supplied by us, complies with the provisions of above-mentioned directive.

Applied harmonized standards in particular:

EN 55011

Specifications, limits and methods of measurement of radio disturbance and medial (ISM) radio-frequency

equipment

EN 50081-1

Electromagnetic compatibility

Part 1: residential, commercial and light

industry

Generic immunity standard

Part 2: industrial environment

Walldorf, 10.08.2004, Dr. Ing. Z. Paluncic Walldorf, 10.08.2004, Dr. Ing. Z. Paluncic

U.S. Patent-No. 6,244,387, German Registration Design No. 29923765.6

Form 403013 2.1A-38006-E05 Page 47 of 48

User Manual


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 2005

Printed in Germany

Web site: www.lincolnindustrial.com

Page 48 of 48 2.1A-38006-E05 Form 403013

No results