Lincoln industrial EM-U2 User manual

LINCOLN GmbH • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone] • Tx 466088
Page 1 of 16
Owner Manual
1.3A-28001-B97
Subject to change without notice
1027a95
Electric Motor-Operated Change-Over Valve
EM-U2 and Electric Motor-Operated 2/2-Way
Valveand3/2-WayValve

1.3A-28001-B97
Owner Manual
Subject to change without notice
Page 2 of 16
LINCOLNGmbH•Postfach1263 • D-69183Walldorf•Tel [phone] • Fax [phone] • Tx466088
This Owner Manual is intended to familiarize the user with the
pump/lubrication system and to enable him to use its various fea-
tures.
The Operating Instructions contain important information for safe,
correct and economic operation of the pump/lubrication system.
Their observance will help avoid hazards, reduce repair costs and
downtime, increase the reliability and prolong the service life of
the pump/lubrication system.
These Operating Instructions must be completed to include the
respective national regulations concerning the prevention of acci-
dents and protection of the environment.
TheOwnerManualmustalwaysbeavailableon the site where the
pump/lubrication system is in operation.
If persons who are charged with work with the pump/lubrication
systemdo not have a good command oftheEnglish language, it is
the user’s responsibility to take the necessary action to make the
Owner Manual, particularly the Safety Notes, understandable to
these persons.
The Owner Manual must be read and used by all persons who are
charged with work with the pump/lubrication system, e.g.
• Operation, including adjustment, troubleshooting during ope-
ration, elimination of production waste, maintenance, dispo-
sal of process materials
• Maintenance (inspection, repairs)
•Transport
Preface of the Owner Manual
Table of Contents
Contents Page
Safety Notes .....................................................................3
Description .......................................................................5
ModelVariants ...................................................................5
Examples of application .....................................................6
Features .............................................................................7
TechnicalData....................................................................7
Mode of Operation .............................................................9
Contents Page
Erection and Assembly.................................................10
Mechanical Installation .................................................... 10
Electrical Installation ........................................................ 10
Operating Instructions..................................................10
Commissioning ................................................................10
Factory Setting .................................................................11
Troubleshooting................................................................12
Spare Parts List .............................................................14

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Page 3 of 16
Owner Manual
1.3A-28001-B97
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The Operating Instructions include general instructions which
must be followed when a pump/pump unit is installed, operated or
serviced. Therefore, it is absolutely necessary for the fitter and
the specialist/user to read the Operating Instructions before a unit
is installed and commissioned. The Operating Instructions must
alwaysbeavailable on the site where the machine/system is erec-
ted.
All general safety instructions contained in this main chapter on
safety must be observed as well as all special safety instructions
given in other main chapters.
Hazard markings in Operating Instructions
The notes referring to safety contained in the Operating Instruc-
tions whose failure to observe them may result in personal injury
are marked by the following symbol
Safety symbol acc. to DIN 4844-W9
This symbol warns of an electrical hazard.
Safety symbol acc. to DIN 4844-W8
If ignoring the safety notes might result in machine damages and
malfunction, the word
CAUTION
is added.
Warnings directly fixed to the machine must always be observed
and must be kept in completely legible condition.
Safety Notes
Staff Qualification and Training
The staff responsible for operation, maintenance, inspection and
installation must be adequately qualified for these jobs. The user
must properly regulate the field of responsibility and supervision
of the personnel. If the personnel is not in command of the neces-
sary expertise, they must receive the appropriate training and in-
structions.
If necessary, this can be done by the manufacturer/supplier on
behalf of the machine user. Furthermore, the user must ensure
that the contents of the Operating Instructions are fully under-
stood by the personnel.
Hazards resulting from failure to observe the safety notes
Failureto heed the safety warningsmay result in damage toequip-
ment and the environment and/or personal injury.
Failure to observe the safety notes may result in the loss of all
claim for damage.
As an example, in the following we list some dangers which may
result from failure to observe the warnings:
• failure of machine/system to fulfill important functions
• failure of specified methods for maintenance and repair
• personal injury due to electrical, mechanical and chemical influ-
ences
• danger to the environment due to leakage of harmful materials
Safety-Conscious Working
The safety notes given in the Operating Instructions, the prevai-
ling national regulations for the prevention of accidents and any
internal working and shop regulations and accident prevention
measures of the user must be observed.
Safety Instructions for the User/Operator
• If warm or cold machine parts may involve hazards, the custo-
mer must protect them against accidental contact.
• Do not remove protection devices for moving parts while the
machine is in operation
• Leakages of harmful materials must be disposed of so as to
jeopardize neither persons nor the environment. The require-
ments of the law must be satisfied.
• Danger caused by electrical current must be excluded (for de-
tails refer to the applicable specifications of VDE and the local
power supply companies).
10013a94
10014a94

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Page 4 of 16
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Safety Instructions for Maintenance, Inspection and Instal-
lation Services
The user must make sure that all maintenance, inspection and
installation work is executed by authorized and qualified experts
who have throroughly read the Operating Instructions. On no ac-
count may work be done on the machine while the machine is in
operation.Followall instructions for shutting down the machine as
described in the Operating Instructions. Decontaminate pumps
and pump units delivering harmful materials.
Reassemble all safety and protection devices immediately after
completion of the cleaning procedure.
Disposeof material harmful to the environment inaccordancewith
the applicable official regulations.
Before putting the pump/pump unit into operation, ensure that all
points given in the chapter „Commissioning“ are fulfilled.
Unauthorized Modification and Spare Parts Production
Alteration and modifications of the machine are only allowed if
approved by the manufacturer. Original spare parts and accesso-
riesauthorized by the manufacturer ensure safeoperation. If other
parts are used, the manufacturer may be released from his liabili-
ty for the resulting consequences.
Inadmissible Operating Modes
The operational safety of the supplied product is only granted if
the product is operated according to the instructions given in
chapter 1 - General - of the Operating Instructions. The max. ra-
tings listed in the Technical Data sheet must never be exceeded.
Commissioning of the product (pump/pump unit) within the Euro-
peanUnionis forbidden until it has been decided that the machine
in question meets the requirements of the EU guidelines.

LINCOLN GmbH • Postfach 1263 • D-69183 Walldorf • Tel [phone] • Fax [phone] • Tx 466088
Page 5 of 16
Owner Manual
1.3A-28001-B97
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Model Variants
The different model possibilities are represented on following chart:
Variants Part number
model with 24 VDC model with 230 VAC
Change-overvalve
(4/2-wayvalve) 618-28387-1 618-28388-1
3/2 -way valve Connection B 625-28448-1 625-28450-1
closed
3/2 -way valve Connection R 625-28449-1 625-28451-1
closed
2/2 -way valve Connection 625-28590-1 625-28591-1
B + R
closed
A B A B
P R P R
M
A A
P R P R
M
Description
2003a95
2004a95
1080a96
2005b97

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Examples of application
The examples of application are represented on following figures.
1031a95
Fig. 2 EM-U2 used as a 3/2-way valve for two-line lubrication systems, with the
possibility to relieve both lines simultaneously
1030a95
Fig. 1 EM-U2 used as a changing-over unit for two-line lubrication systems Fig. 3 EM-U2 used as a 3/2-way valve for filling systems
1029a95
1079a96
Fig. 4 EM-U2 used as a 2/2-way valve for filling systems

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Owner Manual
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Features
• available with 24 V DC and 230 VAC;
• the respective valve position is always reached , irrespective of
thevoltagefluctuations, temperature and lubricant consistency;
• can easily be integrated into electrical control units due to the
electric motor-operation;
• robust and compact construction;
• insensitive to humidity and dirt;
• insensitive to mechanical influences.
Technical Data
Connection thread: 3/4" BSP
Flow rate: Qmax = 65 dm³/h
Operating pressure: pmax = 400 bar
Operating temperature: -20°C to 80°C
Switching time: 0,5 sec.
Soundlevel: < 70 dBA
Supply voltage: 24 V DC or 230 VAC
Powerconsumption Pmax = 80 W
Degree of protection: IP54
Weight: 24 V DC version: 11 kg
230 VAC version: 12.8 kg
fitting position: optional
item description
A main line 1
B main line 2
P pressure line
R relief line
Fig. 5: mounting dimensions of the EM-U2
1037c95
Important:
The change-over valve housing is sluable by 180°

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Page 8 of 16
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Fig. 6: circuit diagram 24 V DC version Fig. 7: circuit diagram 230 VAC version
1033b951032b95

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Page 9 of 16
Owner Manual
1.3A-28001-B97
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• Change-over valve housing (1) operates as a 4/2- or 3/2 way
valve and is actuated by the DC gear motor (3).
• The motor (3) is started by the signal of the end-of-line pressu-
re switch.
Fig. 8: electric motor-operated change-over valve: principle of operation
1036b95
• The rotating motion of the motor (3) is converted by the eccen-
tric (6) and the connecting link (2) into a stroke of the piston (5)
which performs the reversing process.
• Once the piston has reached its opposite position the position
switch (4) switches the motor (3) off. The piston (5) remains in
its position until the motor starts again.
Mode of Operation

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Erection and Assembly of the EM-U2
• When installing the change-over valve, pay attention to the
mounting dimensions shown on Fig. 5
• The change-over valve can be installed in any position.
• Fix it to the housing feet by means of 4 screws M 10.
• Connect the tube lines in accordance with the instructions gi-
ven by the fitting manufacturer.
NOTE: Do not screw fittings with conical thread into the
connections of the change-over valve housing (refer to
Fig. 8 A)
Electrical Installation
• Perform the electrical connection of the change-over valve EM-
U2 according to Fig. 6
• All electrical work should be underta-
ken only by qualified personnel.
Mechanical Installation
Operating Instructions
Commissioning
• Putthechange-over valve into operation in accordance with the
instructions mentioned in the description of the whole system.
• After the first pressure build-up in the main lines check the fit-
tings for leakage. Retighten them if necessary.

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Owner Manual
1.3A-28001-B97
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Fig. 9: piston final position 1
Fig. 10: Piston final position 2
Fig. 11: adjustment in position 2 at dissassembled change-over valve housing
1038a95
1075a95
1075a95
item description
1 connecting link
2 bearing
3 limit switch
4 change-overvalve
Factory Setting
The factory settings are shown on following figures.
In the case of resettings, please refer to Item 4.3: remedy to the
fault „change-over valve operates continuously“.
.

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Page 12 of 16
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Troubleshooting
Do not touch anything between the con-
necting link (Fig.8, item B) and the chan-
ge-over valve housing (Fig. 8, itemA) if the
housing cover is opened and the EM-U2 is
ready for operation.
• Fault: no pressure build-up or pressure build-up too slow
• Cause:
• Line system or two-line metering devices leaking
• Piston and/or change-over valve housing worn
• Remedy:
• Check the lines and metering devices
• Replace the complete change-over valve housing (refer to Fig.
12, item 1)
• Fault: no changing over is released
• Cause:
• Line interruption between the units of the change-over valve
• End-of-line pressure switch does not give any signal
• Remedy:
• Check the electric lines and the fuse of the change-over valve
• Check whether the change-over valve operates by actuating it
manually
Check the adjustment of the change-over valve
Checkthe electric lines between the end-of-line pressureswitch
and the change-over valve
• Fault: the change-over valve operates continuously
• Cause:
• The switching point of the position switch is not reached
• Remedy:
• Check the adjusted value of 20
-0.5
and re-adjust it, if necessary.
• Check the adjustments shown on Fig. 9 - 11 see remedy at
followingfault:”Theline which has been charged after the rever-
sing process is not relieved ”

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Owner Manual
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Fault: The line which has been charged after the reversing process is not relieved or
No pressure build-up in the respective line after the reversing process although the
pressure between the pump and change-over valve increases rapidly.
• Cause:
• The reversing piston does not reach its final position
• Remedy:
• The eccentric continues to operate for a short moment after the
impulse of the position switch. Check internal wiring of the ter-
minal strip (for the 24 V DC version refer to Fig. 12, item 27) and
that of the rectifier (for the 230 V AC version refer to Fig. 12,
item 26)
Replace the terminal block assembly and/or the power supply
assembly, if necessary.
• Check adjustment shown on Fig. 9:
Piston final position 1: the outer edge of the ball bearing must
be centered in the borehole of the connecting link and must be
visible (in the case of old models without borehole in the con-
necting link, the distance between the upper outer edges of the
ball bearing as shown on Fig. 9 and the connecting link must be
8
+1
mm).
Piston final position 2: acc. to Fig. 10: the lower outer edges of
the ball bearing and the connecting link must be aligned (tole-
rance: the outer edge of the ball bearing may lie up to 1 mm
under the connecting link).
If both ball bearing positions are overrun or if the ball bearing
stops before it has reached the positions: check the value of
20
-0.5
and re-adjust it, if necessary.
The ball bearing stops before it has reached its position in pi-
ston final position 1 and overruns the position of piston final
position 2: push the position switch towards the connecting link.
The ball bearing overruns its position in piston final position 1
and stops before it has reached the position of piston final posi-
tion 2: push the position switch away from the connecting link.

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Spare Parts Drawing and Spare Parts List
1028b95
Fig 12: spare parts

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Owner Manual
1.3A-28001-B97
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Spare Part List EM-U2
Item Designation Quantity Part Number
1 change-over valve housing assembly1 518-31801-1
1.1 screw DIN 912 M5 8 201-12017-8
1.2 o-ring 2 219-12224-1
1.3 supporting washer 2 306-17805-1
1.4 u-cup sealing ring 2 220-12234-5
2 gasket 1 306-19592-1
3 housing 1 314-19593-1
4 lock nut 1 237-13352-2
5 cable gland 1 237-13345-7
6 nut DIN 934 M 8 1 207-12135-8
7 connecting link 1 418-23998-1
8 washer DIN 125 10,5 2 209-13077-2
9 screw DIN 912 M 10 2 201-12027-4
10 screw DIN 912 M 6 3 201-12018-5
11 grooved ball bearing DIN 625 1 250-14009-7
12 eccentric 1 418-23996-1
13 retaining ring DIN 471 1 211-12164-1
14 key DIN 6888 1 214-13123-2
15 DC-gear motor 1 245-13599-1
16 screw DIN 84 M 5 2 201-12037-5
17 ground wire 1 664-36878-2
18 screw DIN 912 M 6 4 201-13608-3
19 washer DIN 7603 4 209-13065-2
20 cover 1 314-19594-1
21 sealing ring 0,75 m113-35214-2
22 screw DIN 912 M 5 2 201-12016-6
23 washer DIN 125 2 209-13077-3
24 limit switch assembly 1 518-31895-1
25 fuse 6,3 A 1 237-13426-2
30 tapping screw DIN 7981 - ST 2,2 2 206-13725-8
for 24VDC-version
27 terminal block assembly 1 518-31903-1
28 self-tapping screw DIN 7513 M 4 2 201-12015-2
29 washer DIN 125 2 209-12146-2
for 220VAC-version
26 power supply assembly 1 518-31901-1
28 screw DIN 912 M4 2 201-12015-2
29 washer DIN 125 2 209-12146-2
not shown
for all 3/2-way valves for
closing outlet B or R
wayvalve 625-28448-1
wayvalve 625-28450-1
wayvalve 625-28449-1
wayvalve 625-28451-1
closure plug G 3/4 1 303-17448-2

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Declaration by the manufacturer as defined by
machinery directive 89/392/EEC Annex II B
Herewith we declare that the supplied model of
Electric Motor-Operated Change-Over Valve EM-U2 and
Electric Motor-Operated 2/2-Way Valve and 3/2-Way Valve
is intended to be incorporated into machinery covered by this
directive and must not be put into service until the machinery
into which it is to be incorporated has been declared in con-
formity with the provisions of the directive.
Applied harmonized standards in particular
EN 292 T1/T2
prEN 809
EN 563
Walldorf, 11.03.1997 , ppa. Z.Paluncic