Lincoln industrial QLS 301 Owner's manual

QLS 301 Lubrication System
2.1A-380006-A99 April 1999 Form 402865 Section - Q3 Page - 9
QLS 301
InstallationandOperationInstructions
4197a99
810-55230-1

Page Number 2 of 24
QLS 301
Subject to modifications
2.1B-38006-A99 Form 402865
InstallationandOperationInstructions
Table of Contents
Safety Instructions ......................................................2
Installation Instructions...............................................3
Pump ............................................................................3
SSV Divider Block .........................................................3
Crossporting of the SSV Divider Block.........................3
Check valves .................................................................4
Feedback of supplied lubricant....................................4
Installing Zerk-Locks onto grease fittings ...................4
Connecting Feed Lines ................................................5
Filling of reservoir....................................................5
Setting of lubrication cycle time intervall ................5
Electrical Connection Diagrams ..................................6
QLS 301Selection Guide ..............................................7
Description of QLS 301 ...............................................8
Operating of QLS 301 ..................................................8
Pressure relief valve .....................................................9
Pump Display Window ................................................. 9
Monitoring time/malfunction .........................................9
Acknowledging the malfunction............................10
Low-level control ...................................................10
Acknowledging the low level indication................10
Malfunction/low level indication ............................10
Monitoring relay ...........................................................10
Metering of the lubricant .............................................10
Setting and operation
of the QLS 301 ............................................................ 11
Display mode .............................................................. 11
Operating mode ..........................................................12
Programming mode ...................................................13
Maintenance, Repair and Test ..................................14
Maintenace..................................................................14
Refilling reservoir ..................................................14
Repair..........................................................................14
Functional Test ............................................................14
Troubleshooting .........................................................15
Technical Data ............................................................17
Dimensions ................................................................18
Service Part of the QLS 301......................................19
Manufacturer’s declaration .........................................24
Safety Instructions
Appropriate Use
• Use QLS 301 only for the delivery of lubricants. The pump
is designed for intermittent operation. QLS 301 is desi-
gned of supplying lubricant to a maximum of 18 lube
points per cycle.
• Do not use QLS 301 with SSV block in bottom mounting
position for mobile applications. Don’t install the pump
in areas exposed to shock.
General safety Instructions
• Do not over pressurize reservoir when filling the pump.
Refill QLS 301 pump with clean lubricant.
• Incorrect use may result in bearing damage caused by
poor or over-lubrication.
• Each outlet used must be equipped with an appropriate
check valve see page 4, Fig.3.
• 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.
For pumps with 120 VAC and 230 VAC, switch off the power
supply before beginning maintenance or repair work.
• QLS 301 operates automatically. However, a regular
check (approximately every 2 weeks) should be made to
ensure that lubricant is being dispensed from all lubricant
points.
• Used or contaminated lubricants must be disposed of in
accordance with local environmental regulations, see
technical data sheets of lubricants.
• The manufacturer of the centralized lubrication system
will not accept any liability for:
- damage due to the use of greases which are not or are
only conditionally pumpable in centralized lubrication
systems.
- damage caused by insufficient lubricant and irregular
refilling of pump.
- 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
componenets.
- damage caused by the use of unapproved parts (voids
the pump warrenty).
Operation, Repair and Maintenace
• Repairs should only be performed by authorized
personnel who are familliar with the instructions.
Explanation of symbols:
= explanation
* = describes and action
- = listing within a section
• QLS 301 must only operate with mounted or connected
SSV divider blocks.
• Pump must be regularly refilled with clean lubricant.

Subject to modifications
Page Number 3 of 242.1B-38006-A99
QLS 301
Form 402865
InstallationandOperationInstructions
Installation
• Do not remove, modify or alter any safety equipment
already installed on the machine.
• QLS 301 pump must be kept away from the sources of
heat (see Operating Temperature Specification).
• Follow installation instructions of the OEM regarding
minimum distances between the drilled holes and
welding procedures.
• Use following recommendations to select an installation
location:
- Keep the feed lines as short as possible.
- Provide access to fill, clean and visually monitor the
pump operation.
• Installing QLS 301 pump with the reservoir upright is
perferred, but pump may be installed with the reservoir in
horizontal without affecting its operation.
• The QLS 301 may only be installed by qualified person-
nel. The connection (N/L/PE) of the supply voltage must
be made according to VDE 0100 and VDE 0160.
• Install a protective and lock out device for isolating and
disconnecting the QLS 301. Before beginning the instal-
lation work, disconnect the electrical supply .
• 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 excee-
ded, the device may overheat. It may damage the QLS
301 and thus impair the electric safety.
InstallationInstructions
Pump • Use drilling template to mark and drill mounting holes of
the QLS 301. Drilling template and mounting bolts are
included in the package.
SSV Divider Block Crossporting of the SSV divider blocks
• The outlets of the SSV divider block can be combined to
increase the amount of lubricant for a particular outlet. To
do this, simply plug the unused outlets with the closure
plug (see 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). For instance
plugging outlets 5 and 3 will triple the amount of lubricant
at outlet 1.
•Do not plug outlet numbers 1 and 2 on SSV 8, 12 and 18
of pump models with SSV divider block installed on the
bottom.
Fig.1 - Single double and tripple lubricant output
x -Outlet quantity (single, double, etc.)
1... 10 Outlet numbers
A - Clamping ring (brass)
4163a98
Fig. 2 - Closure plug, provided in the accessory kits
* Install a closure plug in each outlet port hole which is not
required, see Fig. 1 or 4.
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Page Number 4 of 24
QLS 301
Subject to modifications
2.1B-38006-A99 Form 402865
InstallationandOperationInstructions
Installing Zerk-Locks onto grease fittings ( for inch size
accessory kits only)
• The Zerk-Lock fitting consists of the Zerk-Lock body,
insert and a Quicklinc fitting.
* Place the Zerk-Lock body over the grease fitting and place
the staking tool firmly against the Zerk-Lock insert.
(Staking tool is included in the accessory kits, see page
8).
* Strike the tool sharply with a hammer until the Zerk-Lock
insert partially crimps onto the grease fitting.
Fig. 5 - Place the Zerk-Lock
body over the grease fitting
Direct (internal) feedback feature
• All pumps with the back mouted SSV divider block,
starting from serial No. 998000100C/001 are assembled
with outlet 2 plugged for direct feedback capability. To
change the outlet 2 for bearing lubrication, replace
closure plug with check valve (Fig. 3).
• On all pumps with previous serial numbers, never close
outlet 1.
Fig. 4 - Internal feedback of supplied lubricant, only on back-
side mounted SSV divider blocks
Check valves
* Install one complete check valve in each outlet port hole
which will be used, see Fig. 1 and 4.
* For feedlines (dia. 6x1.5 mm, 1/4“ I.D., provided in the
accessory kits) use check valves with standard collar and
knurled flange.
Fig. 3 -Check valve, push-in type
4180a99
x -Outlet quantity (single, A - Clamping ring (brass)
double, etc.) R - Return line borehole
1... 10 Outlet numbers
Fig. 6 - Installation of Zerk-
Locks with staking tool
4201a99
4188b99
Note: To feed back unneeded lubricant quantities from bot-
tom - side mounted divider block to the reservoir, connect
unneeded outlet via feedline to plug 5 (Fig. 14) for external
return line.
Lubrication points
Installing Quicklinc fittings into lube points
(for metric size accessory kits only)
* Remove hydraulic lube fittings from lube points and
install appropriate Quicklinc-fittings into the bore holes of
the lube points.
4200a99
• All pumps with the back mouted SSV divider block,
starting from serial No. 998000100C/001 have the
cabability to feed back unused lubricant from closed
outlets directly to the reservoir internally (see R Fig. 4).
Note: The pumps with previous serial numbers have capabi-
lity to feed back the lubricant directly to the reservoir only
from even outlets. For instance on a SSV 6 devider block, the
outlets 2, 4, 6 are closed.
* To achieve this the outlet 2 should be closed with a
closure plug (see Fig. 2). For instance (see Fig. 4) the
lubricant from outlets 1, 2 and 4 will be internally feed
back to the reservoir, outlet 3 will have double amount
and outlet 6 will have single amout of lubricant.

Subject to modifications
Page Number 5 of 242.1B-38006-A99
QLS 301
Form 402865
InstallationandOperationInstructions
* Screw the Quicklinc fitting into the Zerk-Lock body and
tighten until parts resist further tightening, (about 1-1/2
turns).
• If the lines are not primed, prime all lubrication feed lines
before connecting them to the Zerk-Locks.
• Connect feed lines (dia. 6x1.5 mm, 1/4’’) from the check
valves directly to existing grease fittings using the Zerk-
Lock fittings included with the accessory kit.
Note: Push the end of the line firmly into the Quicklinc fitting
until it is fully seated in the body. The primed feed lines are
marked with white lines (Fig.8, 9) as an installation aid.
Fig. 7 - Screwing Quicklinc fitting into the Zerk-Lock body
Note: Quicklinc hex. is 12 mm. Zerk-Lock body hex is 1/2 ’’ .
* Move the Zerk-Lock and tube fitting from side to side on
the grease fitting to insure the Zerk-Lock is firmly seated.
Fig. 9 - Feed line insert into the fitting up to the next white mark
4157a98
• Cut the pressure plastic tube off at one of the white lines
before it is mounted. 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.
Connection of Feed Lines • Measure, cut and route the feedlines included in the kit.
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).
• Secure the lubrication lines to the machine using nylon
ties, clamps or straps provided in the accessory kit.
Fig. 8 Feed line installed in the Quicklinc fitting
* Cut the fed line off at one of the white lines before it is
mounted.
* Then insert the feed line into the fitting up to the next
white mark.
• This will ensure a correct installation of the feed line in
the tube fitting.
Filling of reservoir
* Fill the reservoir with clean suitable lubricant.
* Expel all air from under follow plate. Make sure that the
follower plate seal moves above the vent hole to ensure
that all air pockets are vented.
Fig. 10 - Vent hole on reservoir 4204a99 Setting of lubrication cycle time interval
* Set the lubrication cycle time interval (see page 13).
4203a99
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Page Number 6 of 24
QLS 301
Subject to modifications
2.1B-38006-A99 Form 402865
InstallationandOperationInstructions
Electrical Connecting Diagrams
Direct current (VDC)
Alternate current (VAC)
Electricalconnection
• 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.
* Connect the electric wires according. to the following
electrical connecting diagrams.
Note: The protection IP6K9K (NEMA 4) is guaranteed when
the socket (x1, x2) is tightened on housing cover with flat
packing.
Fig. 11 - Electrical Connecting Diagram, direct current.
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Fig. 12 - Electrical Connecting Diagram, alternate current.
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Subject to modifications
Page Number 7 of 242.1B-38006-A99
QLS 301
Form 402865
InstallationandOperationInstructions
Pump models
Examples of part numbers P30100810111
P30162410151
P301 6 2 4 1 0 1 5 1
Pump
Forgrease..............................................P301
SSV Divider Block
External, SSV 6, SSV 8**.................................0
External, SSV 12, SSV 18**.............................1
SSV 6 (back)...................................................3
SSV 8 (bottom)................................................4
SSV 12............................................................6
SSV 18............................................................9
SSV Divider Block Position
None.................................................................0
Back.................................................................1
Bottom1.............................................................2
Operating Voltage
12 VDC.............................................................2
24 VDC.............................................................4
120 VAC*..........................................................6
230 VAC*..........................................................8
Reservoir/Low level control
1 l reservoir with low level control....................1
Dry Contacts
None...................................................................0
Yes.....................................................................1
Type of Plug Connector
Square-type, acc. to DIN 43650 type
of construction A................................................1
Electrical Connectors
Without socket, without cable.............................0
With socket, without cable*................................1
With socket, with cable, 10 m.............................5
With socket, with ADR cable, 10 m.....................6
Control p. c. b.
None....................................................................0
Monitored, 1cycle, SSV 12, SSV 18
Monitored, 1, 2, 3 cycles, SSV 6, SSV 8.............1
Example of an explained model number:
Pump model P30131810111 -Grease pump, SSV 6 block mounted on the back, 230 VAC, with low level and without dry contact.
* Note: 1. Standard 12 and 24 VDC pump models are shipped with 10 meter (30’) electrical cable.
2. Standard 120 and 230 VAC pump models are shipped without electrical cable (electrical connection 1 only)
** Note: For external divider block application only use the specific divider blocks SSV ... KNQLS.
On pump models without divider block there is not possible to close cycles without changes on the p. c. b.
1
Note: Do not use QLS 301 with SSV block in bottom mounting position for mobile applications. Dont install
the pump in areas exposed to shock.
Accessory Kits Inch Size Kits: Metric Size Kits:
SSV 6/8 part no. 550-36971-1 SSV 6/8 part no. 550-36970-1***
SSV 12 part no. 550-36971-2 SSV 12 part no. 550-36970-2 ***
SSV 18 part no. 550-36971-3 SSV 18 part no. 550-36970-3 ***
*** Lube fittings must be ordered separately
QLS 301 Selection Guide

Page Number 8 of 24
QLS 301
Subject to modifications
2.1B-38006-A99 Form 402865
InstallationandOperationInstructions
Description of QLS 301
•The QLS 301 is a complete compact lubrication system for
maximum of 18 lubrication points per cycle*.
*Note: More than 18 lubrication points are possible for appli-
cations with limited lubrication requirements. Contact Lincoln
Industrial Technical Sevice for additional information.
• The pump has three basic configurations:
- SSV divider block mounted on the back (see fig. 13)
- SSV divider block mounted on the bottom (see fig. 14)
- Pump without the SSV divider block attached.
• The pump with the SSV divider block mounted on the
bottom has the capability of using steel tubing as lubrica-
tion lines if necessary.
• Standard lubrication lines are high pressure plastic
tubing included in the pump installation kit for pumps
with the SSV divider block attached.
Note: Regardless of the SSV divider, mounting the operation
of the pump is the same.
• A signal from the pump timer starts the electric motor and
pumping element starts pumping the lubricant to the SSV
divider block.
• When all lubrication points have received lubricant, an
internal proximity switch turns the motor off, completing
one lubrication cycle.
• If pump does not complete the cycle within 15 minutes of
operation, alarm message “Er“ will be displayed as a
flashing light in the keypad window.
Fig. 13 - QLS 301 with back position of the SSV divider block
Fig 15. - QLS 301 unit
Operation of QLS 301
Fig. 14 - QLS 301 with bottom position of the SSV divider block
• The QLS 301 operates according to lube cycles (pause
and operating times).
• The pause time begins the cycle, then the operating time
occurs.
• A division of the lube points (option) via secondary
metering devices and one main divider block (SSV 6,
SSV 8) is possible only up to max. 18 points per cycle
(see * Note). In this case, the number of the cycles of the
main divider block must be set (see P 3 on page 13).
4198a99
1 - Proximity switch 3 - SSV divider block
2 - Control pin 4 - Nipple for external manual
lubrication (1/8’’)
4199a99
1 - Connecting block 4 - Nipple for external manual
2 - Manifold lubrication (1/8’’)
3 - SSV divider block 5 - Plug (1/8’’) for
external return line (R)
external pressure line (P)
1 - Low-level control 4 - Control unit
2 - Proximity switch 5 - Pump unit
3 - Keypad with display 6 - SSV 6, 8, 12, 18
4205a99

Subject to modifications
Page Number 9 of 242.1B-38006-A99
QLS 301
Form 402865
InstallationandOperationInstructions
Pressure relief valve
Fig. 16 - Pressure relief valve (cartridge) in housing
• 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 201 bar
(3000 psi).
• If the pressure relief valve is actuated, this indicates that
the system is malfunctioning. The lubricant flows back
into the reservoir (not visible).
• Upon expiration of the monitoring time of 15 minutes, the
pump switches off. The fault indication ”Er” is displayed
on the key pad of the pump. See ”Display mode” under
”Control unit”.
Pump Display Window
• Pump “On” is indicated on the display by an illuminated
decimal point (pause time) (fig. 17).
• Pump
“running” is indicated on the display by a rotating
light movement of the green display (operating time)(fig.
18).
• If the voltage supply is interrupted during the operating
time, the operating time starts again from the beginning
after switching on.
Fig. 18 - Green display (operating time)
Fig. 17 - Green decimal point (pause time)
• Additional lube cycle (Manual Lube)
- is initiated via the button (Fig. 19). Press the button for 2
seconds.
- can be initiated at any time, provided that the power
supply is applied.
Note: If a malfunction is present (flashing display), first ack-
nowledge this malfunction.
• If a fault signal (malfunction) is present, it will be cancel-
led after the system is operating properly.
Monitoring time/malfunction
Fig. 19 - Pushbutton for additional lubrication cycle
Fig. 20 - Display of a fault indication
4208a999
4209a99
4222a99
4210a99
4196a99
• If the cycle is not complete within 15 minutes (monitoring
time) after expiration of the pause time, the pump imme-
dately switches off.
• The fault indication “ Er ” (error) is displayed as a
flashing light (fig. 20). At the same time, a potential free
contact is available for the external fault indication (opti-
on).
• If a malfunction is present, the pump no longer switches
on automatically.

Page Number 10 of 24
QLS 301
Subject to modifications
2.1B-38006-A99 Form 402865
InstallationandOperationInstructions
• The metering of the lubricant occurs via the integrated
divider block (e. g. SSV 8, SSV 12 or SSV 18).
• When the reservoir is nearly empty the pump display
shows “LL” (low level).
• The follower plate (3) (Fig. 24) of the reservoir moves the
pin (2) with the magnet (3) 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 lube cycle is completed. Upon expiration of
the pause time, the pump cannot be started again
automatically. The flashing display “LL” is indicated.
• Before filling the reservoir, press the button Fig. 21 for
acknowledging the low level indication.
• As soon as the lubricant reservoir is filled up, the “LL”
display is cancelled. The lube cycle resumes.
Acknowledging the low level indication
* By pressing the button (Fig.22), the flashing display “LL”
is changed into a continuous light.
Malfunction/low level indication
• If both indications occur at the same time, then both
displays “Er” and “LL” will flash.
Fig. 21 - Keypad with showing a malfunction
Fig. 22 - Acknowledging the malfunction
Fig. 23 - Display of a low-level control
Fig. 24 - Parts of low level control
1 - Magnet 3 - Follower plate
2 - Pin
Metering of the lubricant
• In this case, switch on the pump by pressing the button
for additional lube cycle, see Fig. 18. Acknowledge the
malfunction before doing so.
• When a malfunction is present, it can only be cancelled
by initiating an additional lube cycle and after a proper
lube cycle has been executed afterward.
• If the fault is still present after an additional lube cycle
has been initiated, the fault indication “Er” is displayed
again.
• The monitoring time starts at the same time as the
operating time. It is a fixed time of 15 minutes.
• If the voltage supply is interrupted during the monitoring
phase (operating time), the monitoring time starts from
the beginning after the pump is switched on again.
Acknowledging the malfunction
• On pressing the button (Fig.22 ), the flashing display “Er”
changes into a continuous light.
Monitoring relay
• The monitoring relay signals a low level condition or a
malfunction. In both cases, the monitoring relay will pick
up. The signal is available via a potential free contact.
The monitoring relay is released upon acknowledgement
of the fault. The flashing indication switches to conti-
nuous indication.
Models with Low-level control
4228a99
4214a99
4211a99
4229a99
4230a99
Fig. 25 -Bottom mounting position of divider block