SKF LINCOLN QLS 301 Installation Instructions Manual

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Lubrication System QLS 301 / QLS 401

min

Version 02

Installation Instructions

Following Machinery Directive 2006/42/EC

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Summary of Contents for SKF LINCOLN QLS 301

Page 1 Installation Instructions Following Machinery Directive 2006/42/EC Lubrication System QLS 301 / QLS 401 Version 02...
Page 2 EC Declaration of Incorporation EC Declaration of incorporation following machinery directive 2006/42/EC, Annex II Part 1 B The manufacturer SKF Lubrication Systems Germany GmbH - Walldorf Plant - Heinrich-Hertz-Str. 2-8, DE - 69190 Walldorf hereby declares that the partly completed machinery Designation:...
Page 3 Europe / Africa / Middle East / India wing machinery directive 2006/42/EC are mation on the warranty. This can be found SKF Lubrication Systems Germany GmbH part of the described products and must be in the general terms and conditions.
Page 4 Table of contents Table of contents Installation instructions 2. Lubricants 4. Technical data EC Declaration of incorporation General information Factory settings Legal disclosure Selection of lubricants Tightening torques Table of contents Approved lubricants Explanation of symbols and signs Lubricants and the environment 5.
Page 5 Inhaltsverzeichnis 8. Operation/ shutdown and disposal 11.1 SSV metering device Circuit diagrams 11.2 SSVDV metering device 12.1 Legend General information 11.3 Metering screws of the 12.2 Core assignment of the Temporary shutdown SSVDV metering device connection plugs Shutdown and disposal 11.4 Kit of seals 12.3 12/24 VDC with control pcb, square 11.5 Membrane keypad...
Page 6 Explanations of symbols and signs Explanation of symbols and signs You will find these symbols, which warn of Please heed these instructions and proceed Symbols used specific dangers to persons, material assets, with special care in such cases. Please for- Meaning Symbol or the environment, next to all safety inst-...
Page 7 Explanation of symbols and signs Abbreviations and conversion factors Abbreviations regarding ounce approx. approximately pounds per square inch °C degrees Celsius relative humidity cu.in cubic inch second dB (A) sound pressure level sq.in. square inch i.e. that is e.g. for example etc.
Page 8 1. Safety instructions 1. Safety instructions 1.1 General safety instructions 1.2 General behaviour when handling the product ○ The product may only be used in aware- ○ Protective and safety mechanisms must In addition, the owner must also ensure that the relevant personnel are fully familiar with ness of the potential dangers, in proper not be removed, modified, or disabled...
Page 9 The definition of qualified personnel and the Product training can also be performed by prohibition against employing non-qualified SKF in exchange for costs incurred. personnel are laid down in DIN VDE 0105 and IEC 364.
Page 10 1. Safety instructions 1.4 Electrical current hazard 1.5 System pressure hazard 1.6 Operation The following must be observed during commissioning and operation: WARNING WARNING ○ All information within this manual and Electric shock System pressure the information within the referenced Working on products not discon- During operation the product is documents.
Page 11 1. Safety instructions 1.7 Assembly, maintenance, malfunctions, shutdown, disposal ○ All relevant persons (e.g. operating per- ○ Other units of the superior machine must sonnel, supervisors) must be informed not be damaged or impaired in their fun- of the activity prior to the start of work. ction by the installation of the product.
Page 12 1. Safety instructions 1.8 Intended use 1.11 Referenced documents ○ the use to feed/ forward/ store Group 1 The QLS system is designed to supply lubricants intermittently in a centralized lu- dangerous fluids according to Directive In addition to these instructions, the fol- brication system following the specifications 67/548/EC.
Page 13 1. Safety instructions 1.12 Residual risks Residual risk Remedy Life cycle assembly, malfunction, troubleshooting, repair, maintenance Electric shock due to defective connection • Check connection cable for damages cable People slipping due to floor contaminati- • Exercise caution when connecting the product‘s hydraulic connections on with spilled/ leaked lubricant •...
Page 14 2. Lubricants 2. Lubricants 2.1 General information 2.2 Selection of lubricants ning written approval from SKF Lubrication ATTENTION ATTENTION Systems. No products manufactured by SKF Lubrica- Observe the instructions from the machine All products may be used only for their in-...
Page 15 The product described here can be operated ATTENTION ATTENTION using lubricants that meet the specifications If required SKF can help customers to Only lubricants approved for the product in the technical data. Depending on the select suitable components for feeding the may be used.
Page 16 2. Lubricants 2.4 Lubricants and the environment 2.5 Lubricant hazards ATTENTION WARNING Lubricants may pollute ground and wa- Risk of slipping and injury ters. Lubricants have to be handled and Leaking lubricant is hazardous disposed of properly. Relevant applicable due to the risk of slipping and inju- regulations and laws regarding the disposal ry.
Page 17 3. Overview/ functional description 3. Overview/ functional description Overview Fig. 1 1 Reservoir The reservoir serves to store the lubricant. Corresponding to the pump versions different reservoir versions are available, e.g. with follo- wer plate (QLS 301) or with stirring paddle for grease (QLS 401).
Page 18 3. Overview/ functional description Overview Fig. 2 5 Power supply Serves to connect the pump to an exter- nal power supply. 6 Signal line Serves to connect the pump to an external control or signal device. 7 Metering device Serves to meter and distribute lubricant as well as to switch off the pump by means of an indicator pin and proximity switch after reaching the preset number...
Page 19 3. Overview/ functional description 3.1 Described versions of the QLS systems Overview Fig. 3 Overview Fig. 4 QLS 301 QLS 301 QLS 401 QLS 401 with control unit without control unit with control unit without control unit QLS 301 QLS 401 - with follower plate - without follower plate - with or without control unit...
Page 20 3. Overview/ functional description 3.2 Attachment positions of the SSV metering devices Pump for external metering device Fig. 7 Rear-side mounted metering device Fig. 5 Bottom mounted metering device Fig. 6 ○ with external return of lubricant via The connection (11) for the proximity switch ○...
Page 21 3. Overview/ functional description 3.3 Changing of the output volume 3.4 Changing of the output volume of the SSV metering devices SSVDV metering devices About 0.2 ccm of lubricant are supplied per stroke The output of an SSVDV metering device can be and outlet.
Page 22 3. Overview/ functional description 3.5 Return of unneeded lubricant to the QLS pump Rear-side mounted metering device Bottom mounted metering device External metering device Lubricant return is realized externally via Lubricant return is realized via return line Return is realized internally: return line ”R”...
Page 23 3. Overview/ functional description 3.6 Membrane keypad In case of pumps with control unit the mem- Membrane keypad with display Fig. 13 brane keypad with display serves to: • display operation states and error codes • trigger an additional lubrication •...
Page 24 3. Overview/ functional description 3.8 Displays in the programming mode 3.7 Displays in the display mode Programming step P1 Ready for operation In this step the hourly data of the pause time is The pump is in the pause mode. There are no fault set.
Page 25 3. Overview/ functional description End of programming Start stage SP When switched on, the pump starts with the pau- The display appears shortly as soon as program- se time. Programming step P6. ming step P6 has been confirmed. Normally closed contact Start stage SO Output signal is preset as normally closed contact.
Page 26 3. Overview/ functional description Shows the number of automatically triggered Shows the number of manually triggered addi- operating cycles. Counter value 0-9999 (con- tional lubrication cycles. Counter value 0-9999 tinuous). The display consists of 3 subsequent (continuous). The display consists of 3 subsequent displays alternating in a two second interval.
Page 27 4. Technical data 4. Technical data Pump version 12 VDC 24 VDC 120 VAC 230 VAC -25 °C to 70 °C Admissible operating temperature Operating pressure max. 205 bar QLS 301 any* Mounting position QLS 401 upright * also rotating installations like e.g. in wind power plants. Maximum rotational speed and maximum distance to the hub on request. Lubricants NLGI II greases / NLGI 00, 000 fluid greases Lubrication points...
Page 28 4. Technical data Pump version 12 VDC 24 VDC 120 VAC 230 VAC IP protection class of bayonet plug 6K9K 6K9K Power supply with square plug (left side) Power supply with bayonet plug (left side) Power supply and fault signal with bayonet plug (left side) Fault signal with square plug (right side) Protective and disconnecting device required for isolation...
Page 29 4. Technical data 4.1 Factory settings Programming step / value Factory setting Setting range P1 Pause time in hours* 0-59 h P2 Pause time in minutes* 0 min 0-59 min P3 Metering device cycles per operating cycle 1 cycle 1-5 cycle P4 Signal output fault relay no contact/ nc contact -- (no differentiation)
Page 30 4. Technical data 4.2 Tightening torques Adhere to the following tightening torques when carrying out any assembly or repair works on the pump. Pump to base, machine or vehicle 18 Nm ± 1 Nm Metering device to QLS pump 9 Nm ± 1 Nm Pump element to pump housing 25 Nm ±...
Page 31 5.5 General notes related to storage ○ The product(s) can be wrapped in plastic film to provide low-dust storage. ○ Protection against ground moisture by storing on a shelf or wooden pallet. 5.3 Storage SKF products are subject to the following storage conditions:...
Page 32 6. Assembly 6. Assembly 6.1 General information the packaging material and any shipping ○ Other units must not be damaged by as- Only qualified technical personnel may braces (e.g. plugs) must be removed. install, operate, maintain, and repair the The packaging material must be preserved sembly work.
Page 33 6. Assembly 6.3 Minimum assembly dimensions To ensure sufficient space for maintenance works or for a possible disassembly of the product, provide a space of 50 mm in each direction in addition to the stated dimensions. Minimum assembly dimensions Fig. 15 A = height 230 mm (1L reservoir)* A = height 313 mm (2L reservoir)* B = width 237 mm...
Page 34 6. Assembly Connecting dimensions Fig. 16 6.4 Connection dimensions 6.5 Blockschaltbild Connecting dimensions The pump is fastened on the two mounting Display E = hole distance 146 mm holes. To fasten the pump use the fastening Bedienfeld F = height 110 mm material included in the scope of delivery: Kabeldurchführungen...
Page 35 6. Assembly 6.5 Electrical connection Bayonet plug Electrical connections must be realized in • In case of a bayonet plug without cable such way that there are not transmitted any configure it with a suitable cable. For con- forces to the product (stressless connection). nection of cable, see the circuit diagram For electrical connection, proceed as follows: in these Instructions (chapter 12).
Page 36 6. Assembly 6.6 Priming To prime the system proceed as follows: Now the pump is ready for operation with • Mount primed lubricant lines to the open the factory settings (4.1) or can be ad- outlets of the metering device and then •...
Page 37 6. Assembly Programming steps 6.7 Programming A = Proramming step P1 Pause time setting in hours To program QLS pumps with control unit B = Possible value P2 Pause time setting in minutes proceed as illustrated in the following pro- C = Change value by pressing the key P3 Metering device cycle setting per gramming scheme:...
Page 38 7. Start-up 7. Start-up 7.1 General information 7.2 Trigger additional lubrication Trigger additional lubrication Fig. 20 To trigger an additional lubrication cycle pro- Start-up of the complete and correctly ceed as follows: mounted QLS pump is effected via the • Press the 3.3 key for at least 2 seconds. machine contact or driving switch.
Page 39 8. Operation, shutdown and disposal 8. Operation, shutdown and disposal 8.3 Shutdown and disposal 8.1 General information After the correct electrical connection and If the product will be permanently shut filling with lubricant the QLS pump is ready down, the local regulations and laws regar- for operation.
Page 40 9. Maintenance, cleaning and repair 9. Maintenance, cleaning and repair 9.1 General information • Remove blue plug (10.1) from the printed Replacement of membrane keypad Fig. 22 The warranty does not apply for defects circuit board. arising from improper maintenance, repair •...
Page 41 10. Troubleshooting 10. Troubleshooting Fault Possible cause Remedy ○ Indicator pin on metering device does ○ Check whether indicator pin moves not move within switching range of pro- centrally at a distance of 0.5 mm in front ximity switch, i.e. switching distance of the switching area of the proximity >...
Page 42 10. Troubleshooting Fault Possible cause Remedy ○ Fault in one or several downstream lub- ○ Loosen the lubricant feed lines on the rication circuits or in the bearing points. metering device one after the other to determine where the blockade is loca- Pump runs but does not supply.
Page 43 11. Spare parts 11. Spare parts The spare parts of the QLS system serve as spare parts for identical defective parts exclusively. Modifications on existing pumps are not allowed (exception: metering screws). 11.1 SSV metering devices 11.2 SSVDV metering devices Application QLS 301 / QLS 401 Qty.
Page 44 11. Spare parts 11.3 Metering screws for SSVDV metering devices Code Length Output/stroke Qty. Part no. 008 / A 46.7 mm 0.08 ccm / stroke 12 549-34254-1 014 / B 45.9 mm 0.14 ccm / stroke 12 549-34254-2 020 / C 46.7 mm 0.20 ccm / stroke 12...
Page 45 11. Spare parts 11.5 Membrane keypad Application QLS 301 and QLS 401 with control unit Qty. Part no. Membrane keypad, self-adhesive 236-14340-1 11.6 Pump element Qty. Part no. Pump element D6 650-28856-1 11.7 Adapter M 22 x 1.5 Qty. Part no. Adapter M 22 x 1.5 304-19619-1 11.8...
Page 46 11. Spare parts 11.9 Reservoir QLS 301 / QLS 401 application Qty. Part no. Transparent reservoir, 1 litre with seal and labels 550-36979-2 QLS 401 application Qty. Part no. Transparent reservoir, 2 litres with seal and labels 550-34179-4 11.10 Housing covers QLS 301 application Qty.
Page 47 11. Spare parts 11.11 Motors Name Qty. Part no. Pump motor for 12 V DC 550-36982-1 Pump motor for 24 V DC 550-36982-2 11.12 Motor connections Motor connection V DC 664-34290-3 11.13 Electrical connections Square plug, connection socket with 10 m cable (4- core) 664-36078-7 Bayonet plug, connection socket with 10 m cable (4-core) 1 664-34045-1...
Page 48 12. Circuit diagrams 12. Circuit diagrams 12.1 Legend Cable colours following IEC 60757 Abbreviation Colour Abbreviation Colour Abbreviation Colour Abbreviation Colour Black Green White Pink Brown Yellow Orange Turquoise Blue Violet Components Abbreviation Meaning Abbreviation Meaning Plug for A1 connection Low level Plug for A2 connection Low level with pre-warning...
Page 49 12. Circuit diagrams 12.2 Core assignments of the connecting plugs Core assignment of Core assignment of Core assignment of A1 / X1 connection A2 / X2 connection A1 / X1 connection Pin 1 Pin 2 Pin 3 Pin 1 Pin 2 Pin 3 Pin 1 Pin 2...
Page 50 12. Circuit diagrams 12.3) 12/24 VDC with control PCB, square plug and external metering device...
Page 51 12. Circuit diagrams 12.4) 120 VAC (60 Hz) / 230 VAC (50/60 Hz) with control PCB, square plug and attached metering device (L1) L1...
Page 52 12. Circuit diagrams 12.5) 230 VAC with control PCB, square plug and external metering device...
Page 53 12. Circuit diagrams 12.6) 12/24 VDC with control PCB, bayonet plug and attached metering device 3 WH (15) 12/24 VDC (31) (M+) (M-) AK I max. 2A U max.48V...
Page 54 12. Circuit diagrams 12.7) 12/24 VDC with control PCB, bayonet plug and external metering device...
Page 55 12. Circuit diagrams 12.8) 12/24 VDC with control PCB, square plug and attached metering device...
Page 56 12. Circuit diagrams 12.9) 230 VAC without control PCB, with square plug, cycle counter and attached metering device 230 VAC / 50 Hz 24 VDC...
Page 57 12. Circuit diagrams 12.10) 12/24 VDC without control PCB, with square plug, low level signal and attached metering device 12/24 VDC GN / YE...
Page 58 A global presence provides SKF customers uniform quality standards and worldwide product availability. Important information on product usage All products from SKF may be used only for their intended purpose as described in this brochure and in any instructions. If operating instructions are supplied with the products, they 951-171-003-EN must be read and followed.

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