Lincoln industrial B Series User manual

PL-2000
Series B
The Breakthrough in automating
manual grease lubrication
Owner’s Manual
OneLincoln Way
St.Louis, Missouri 63120-1578
[phone] Copyright 1997
Printedin U.S.A.
FORM 402825

PL-2000 Owner's Manual
3
Index
Lubricator Instructions Page Number
Description .......................................................................................... 4
Lubricator Mounting Instructions......................................................5-6
Lubricator Mounting "Template" ........................................................ 15
Installing Grease Lines..................................................................... 6-7
Electrical Wiring................................................................................... 8
Setting the Timer................................................................................. 9
"Override" (manual lube) Fitting ........................................................ 10
Filling the Reservoir .......................................................................... 10
Manual Lube Button .......................................................................... 10
Remote Monitor Option ..................................................................... 11
Disposal Information ......................................................................... 12
Troubleshooting Chart ....................................................................... 13
Replacement Parts List ..................................................................... 14
Specifications, Dimensions & Packing List................... Separate Sheet

PL-2000 Owner's Manual
4
Description
The Lincoln PL-2000 is a programmable lubrication
system that can supply grease to a maximum of 18
fittings. It can dispense NLGI #2 grease at timed
intervals from 2 hours to 30 days. Each cycle of the
system dispenses .012 in³. of grease per outlet.
The lubricant reservoir is divided by a special dia-
phragm, with the upper portion of the reservoir
precharged for life with nitrogen gas. Filling the
reservoir with grease provides the pressure neces-
sary to dispense lubricant to the fittings.
A signal from the system timer opens a solenoid
valve and allows lubricant from the reservoir to flow to
a divider valve. When all grease fittings have re-
ceived lubricant, an internal cycle switch turns the
system off, completing one lubrication cycle.
The lube timer has a memory. If power is turned off
for less than 72 hours, it “remembers” where it
stopped, and will restart at the same point when
power is restored. (This prevents over-lubrication of
the machine if power is switched on and off over short
periods of time.) If power is off for more than 72
hours, the timer will begin a lube cycle when power
turns on, then start timing toward the previously
selected lubrication interval.
Installation Instructions
Use the following recommendations to select a
mounting location for the PL-2000 lubricator.
• Keep the feed lines as short as possible.
• Provide access to fill, clean, and monitor the
PL-2000.
• Allow adequate room for mounting and connecting
feed lines to the PL-2000.
• Installing the PL-2000 with the reservoir on top is
preferred, but it may be installed in any orientation
without affecting its operation.

PL-2000 Owner's Manual
5
Installation Instructions (cont.)
1) To remove the bezel cover:
Caution: A short ribbon cable runs from the
bezel cover to the timer card. Unplug
the cable before removing the bezel
cover completely, or you may damage
the timer card.
• Remove two screws
• Unclasp the hooks at the front of the bezel
cover from the body of the PL-2000
• Rotate the cover up towards the reservoir,
pulling it slightly away from the body, exposing
the ribbon cable to the timer card.
• Slide the timer card out of the body just enough
to remove the ribbon cable connector from the
timer.
• Completely remove the bezel cover and set it
aside.
Note: When reinstalling the bezel cover, be careful
not to crimp the ribbon cable between the
bezel cover and lubricator body.
2) Determine the mounting location, then:
• The lubricator weighs approximately 20 pounds.
Be sure the mounting location will support the
weight.
• Drill two 7/16 holes spaced 4-1/2" apart, or
• Use template provided on page 15 to locate
holes.
• Fasten the PL-2000 to the machine, using the
mounting tabs and 3/8" bolts provided, as
shown in photograph at right.

PL-2000 Owner's Manual
6
Installation Instructions (cont.)
3) Route the feed lines (included with kit) from the
PL-2000 to the grease fittings, and cut to length.
Caution: Be sure to keep cut ends square and
clean to avoid leaks.
• Keep the lines short as possible.
(Feed lines should not exceed 15' at tempera-
tures below 0°F when using NLGI #2 grease.)
• Avoid sharp bends or moving parts of the
machine which could damage the tubing.
• If grease fitting is located on a moving part,
leave a loop in the feed line large enough to
accommodate the movement.
4) Outlets can be combined to increase the amount
of grease that goes to a single fitting. To do this,
simply replace the tubing adapter with a closure
plug and gasket in one or more outlets. Lubricant
from a plugged outlet is redirected to the next
outlet on the same side of the divider valve-on a
12 outlet system in descending numerical order
and on an 18 outlet system in ascending
numerical order. Example: Plugging outlets 5 &
3 will triple the amount of grease at outlet 1 (as
shown on 12 outlet system at right).
• Closure plugs and gaskets are provided with
this kit.
Important Note:
Do not plug outlets 1 and 2 on 12 point
systems. Do not plug outlets 17 and 18 on
18 point systems. Plugging these outlets
will stop the flow of grease from all outlets.
• Connect the feed lines to the PL-2000 by
pushing the end of each tube firmly into the
Quicklinc fittings at the outlets of the divider
valve, as far as they will go.
Important Note:
Never feed grease from one outlet to more
than one fitting. Grease flow to more than
one fitting will not be positively controlled
and will result in under or over lubrication.

PL-2000 Owner's Manual
7
Installation Instructions (cont.)
5) Secure feed lines to the machine using clamps or
straps.
6) Connect feed lines directly to existing grease
fittings using the Zerk-LockTM fittings included with
the kit. The Zerk-Lock fitting consists of the
Zerk-Lock body, insert, and a QuicklincTM fitting.
• Place the Zerk-Lock body over the grease fitting
and place the staking tool firmly against the
Zerk-Lock insert. (Staking tool included in the
kit.) Strike the tool sharply with a hammer until
the Zerk-Lock insert partially crimps onto the
grease fitting.
• 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 1/2". Zerk-Lock body hex is 12mm.
• Move the Zerk-Lock and tube fitting from side to
side on the grease fitting to insure the Zerk-
Lock is firmly seated.
• Push the end of the feed line firmly into the
Quicklinc fitting until it is fully seated in the body.

PL-2000 Owner's Manual
8
Installation Instructions (cont.)
7) Do not turn on the power to the timer yet.
Run electrical power to the PL-2000. Refer to the
name plate on the right side of the PL-2000 unit
for the electrical requirements of the model you
have. All wiring should conform to the National
Electric Code and any local ordinances and
codes.
Direct Current (DC) operated PL-2000 (See
illustration below.
• Connect the RED wire from the PL-2000 to the
POSITIVE terminal of the DC power source.
• Connect the BLACK wire to the NEGATIVE
terminal of the DC power source.
Alternating Current (AC) operated PL-2000
120 Volt (See illustration below)
• Connect the GREEN wire to the equipment
GROUNDING terminal of the power source.
• Connect the WHITE wire to the NEUTRAL
terminal of the power source.
• Connect the BLACK wire to the HOT or L1
terminal of the power source.
Battery or
DCPower
Source
Red
Black PL-2000
PowerCord
To grounding
terminal To L1 or
hot terminal To neutral terminal
Green
Black White PL-2000
PowerCord
Alternating Current (AC) operated PL-2000
230 Volt (for North American use):
• Connect the GREEN/YELLOW wire to the
equipment GROUNDING terminal of the power
source.
• Connect the BLUE wire to the HOT OR UN-
GROUNDED terminal of the power source.
• Connect the BROWN wire to the HOT or
UNGROUNDED terminal of the power source.
To grounding
terminal To ungrounded
or hot terminal To ungrounded or hot terminal
Green/Yellow
Brown Blue PL-2000
PowerCord
12 to 24 Volt DC
120 volt AC
Connections
230 volt AC
Connections
(North American)
230 Volt (for continental European use):
Note: The supplied cord meets European
CEE color coding standards.
• Connect the GREEN/YELLOW wire to the
equipment GROUNDING terminal of the power
source.
• Connect the BLUE wire to the NEUTRAL
terminal of the power source.
• Connect the BROWN wire to the HOT or L1
terminal of the power source.
To grounding
terminal To L1 or
hot terminal To neutral terminal
Green/Yellow
Brown Blue PL-2000
PowerCord
230 volt AC
Connections
(European Color Code)

PL-2000 Owner's Manual
9
3) Based on the machine lubrication requirements,
set the desired cycle times on switches #1
through #5. Per the following illustrations.
Testing Cycle
Timer test function:
Placing timer switches #1 through #5 as shown
places the timer in the test mode. The test mode will
provide 20 seconds between lube cycles.
4) Before reinstalling the bezel cover, push the
ribbon cable connector over the two pins on the
timer card (just behind the switches). Then
carefully slide the timer card assembly back into
the enclosure, checking to insure that all con-
necting wires are still plugged into the timer card.
Replace the bezel cover.
Note: When reinstalling the bezel cover, be careful
not to crimp the ribbon cable between the
bezel cover and lubricator body.
Two hour time increments Two day (48 hour) time increments
Setting the Cycle Time
WARNING
Turn off and lock out power to the PL-2000
before opening the enclosure.
1) Remove the bezel cover from the front of the
PL-2000.
Caution: A short ribbon cable runs from the bezel
cover to the timer card. Unplug the cable
before removing the bezel cover com-
pletely, or you may damage the timer
card.
2) Timer switches are accessible at the front side of
the circuit card.

PL-2000 Owner's Manual
10
Initial Start-up & Operation
Both the FILL and OVERRIDE fittings are behind a
protective cover which swings open in a counter
clockwise direction.
As with all lubrication systems, lubricant is to be
clean and free of foreign material and grit. Filter if
necessary.
1) Purge system:
Pump grease into the OVERRIDE fitting until you
see lubricant flowing at all the bearing seals.
•Grease pumped through the override fitting
bypasses the timer controlled valve and
reservoir and goes directly through the
divider valve block to the grease fittings.
2) Fill the reservoir:
• Pump grease into the FILL fitting. The reservoir
is full when the needle on the LEVEL INDICA-
TOR reaches the top of the green READY area.
DO NOT OVER FILL. The PL-2000 is
equipped with a safety relief valve which will
discharge lubricant if the reservoir is overfilled.
3) To apply power for the first time:
• Turn on power to the unit.
• The MONITOR light will come on if power has
been off more than 72 hours, indicating that a
lube cycle is taking place. It will turn off when
the lubrication cycle is complete.
• Lubricant will begin to flow to the grease fittings.
4) Monitor light:
• Will stay on until the lubrication cycle is com-
pleted.
• Will stay on longer as the lubricant level in the
reservoir decreases. (This is normal.)
5) Manual Lube button:
• Will initiate a lube cycle when pushed.
• Is used as a check to see if the system is
operating properly
• Is used when you want to lubricate between
preset lube cycles.
Note:Pushing the manual lube button resets the timer
card, causing it to wait the full preset interval
before initiating the next automatic lube cycle.

PL-2000 Owner's Manual
11
Remote Monitor Option
• Two terminals connecting to dry relay contacts on
the timer circuit card can be used to send a
remote indication of a lube cycle.
• The relay contacts close with each lube event
and open on completion of the event.
• Contacts are UL/CSA rated for 5A @125 VAC,
1/10 HP, 5A @30 VDC.
• Suggested use: Warning light or sound device,
signal for machine controller, etc.
• To access the relay contacts, a hole must be
drilled into the side of the enclosure. Hole will be
used to run wires from relay contacts to warning
device.
WARNING
Disconnect power before removing timer board.
Then drill into enclosure. See diagram below for
hole specifications.
• Use appropriate cord connector, such as Kellems
part number HJ1006G or equivalent. If neces-
sary, take measures to seal the cord and cord
connector against moisture.
Timer circuit card
Lamp
Warning Device
1.813 (1-13/16
0.656 (21/32)
.563 (9/16)

PL-2000 Owner's Manual
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Special instructions for handling or
removal of PL-2000 from service:
IMPORTANT: Vent pressure from the
lubricant reservoir before handling the
unit in any way, and before removing it
from its installed position.
Venting lube pressure from reservoir:
• KEEP EYES AND HANDS AWAY FROM THE
VENT PORT. See photos at right.
• DO NOT REMOVE VENT SCREW
COMPLETELY FROM BODY.
• DO NOT TURN VENT SCREW MORE THAN
ONE TURN COUNTERCLOCKWISE.
• OPEN SLOWLY.
• Open VENT VALVE on the top left side of the unit
by turning counterclockwise, one turn or less,
with a 7/32" Allen Wrench.
• Leave vent screw open until all lubricant flow
stops.
Removal from service:
If the PL-2000 unit is to be taken out of service, do
not throw in the trash. The grease reservoir is
charged for life and all units are to be returned to
Lincoln or an Authorized Lincoln Distributor for proper
disposal. The units are to be vented prior to removal
from the machine. (See Venting Lube Pressure
above.)
IMPORTANT: For disposal instructions, contact
Lincoln Technical Services Dept. at 1-314-679-4200,
ext. 782.
Vent Screw Location
Vent Port Location where grease will
discharge when vent screw is opened.

PL-2000 Owner's Manual
13
Trouble Shooting Chart
Symptom
Monitor Light stays on. No apparent
lubricant delivery to lube points.
Monitor light does not turn on.
No apparent lubricant delivery to lube
points.
Monitor light does not turn on.
No apparent lubricant delivery to lube
points. Pressing Manual Lube button
has no effect.
Monitor light does not turn on. Lube
points appear to be getting normal
amount of lubricant.
Lube points are over lubricated,
otherwise PL-2000 appears to operate
normally.
Lube points are over lubricated.
Reservoir is empty. Upon refilling
reservoir, PL-2000 continues to deliver
lubricant to lube point after monitor
light turns off.
Possible Cause
Reservoir empty
Reservoir overfilled
Wire connections to timer are loose or
incorrectly wired.
Blocked feed line.
Low voltage or incorrect current to
PL-2000.
The PL-2000 may be in the process of
a lube cycle.
Closure plug may be installed in wrong
outlet port of divider valve. (See
important note on page 6.)
Low voltage, incorrect current or no
power supplied to PL-2000.
PL-2000 may be between lube cycles.
Timer failure.
Incorrect or no power supplied to PL-
2000.
Timer failure.
Time settings incorrect for application
and need to be revised.
Failure of lubrication unit.
Dirt or foreign matter in lubricant
supply.
Solution
Fill reservoir
Bleed off some lubricant from reservoir
using vent valve.
Check that timer connections are tight and
correct.
Loosen fittings are divider valve outlets until
lubricant, under pressure, emerges from
one outlet. This indicates the blocked feed
line. Trace to determine cause of blockage
and resolve problem. Check for kinks or
collapsed feed line.
Check that the power source supplying
power to the PL-2000 matches the name
plate requirements.
Wait until the lube cycle is completed.
Check the reservoir level gage, lubricant
level may be getting low. Refill reservoir to
correct level.
Remove closure plug and install in correct
outlet port. (See page 6.)
Check that the power source supplying
power to the PL-2000 matches the name
plate requirements, and it is turned on.
Press manual lube button, monitor light
should light and lubricant should be
delivered to bearing. Check time switches
for correct settings.
Replace timer assembly.
Check that the power source supplying
power to the PL-2000 matches the name
plate requirements and it is turned on.
Replace timer assembly.
Confirm proper time settings. Revise time
settings as required.
Obtain service or replace.
Using clean lubricant, free of dirt and grit,
pump lubricant into Override fitting. Check
for proper operation. Refill reservoir with
clean lubricant.

PL-2000 Owner's Manual
14
Replacement Parts
Part
Number
241054
241055
241056
244047
244883
247340
250687
250707
250719
251240
251254
209121582
303174992
Std.
Pkg.
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Nylon cable ties (7") (100 pcs.)
Nylon cable ties (7") (50 pcs.)
Nylon cable ties (7") (25 pcs.)
Quicklinc Fitting (for Zerk-Lock)
Quicklinc fitting (lubricator outlet)
Zerk-LockTM fitting
1/4" (.250) OD X .050"
Wall Nylon Tubing (50')
DC timer ass'y.
ACtimerass'y. (120VAC)
AC timer ass'y (230 VAC)
Bezel cover ass'y.
Gasket (closure plug)
Closure plug

PL-2000 Owner's Manual
15
Removetemplate alongperforation.