Schaeffler CONCEPT4 User manual

Lubricators
CONCEPT4
User manual

Foreword
Lubricators CONCEPT4 work with minimal quantity lubrication,
which ensures the controlled and efficient supply of lubrication
points with selected, very high quality lubricants. The lubricators
contain highly efficient, microprocessor-controlled piston pumps.
Each piston pump has two outlets. Lubrication intervals and
lubrication quantities can be set individually for each lubricant
outlet under PLC control.
Current version A current electronic version (.pdf) of this user manual
can be found at:
http://medien.schaeffler.com using the search term BA 67.

2 BA 67 Schaeffler Technologies
Page
Contents
About the
user manual
Symbols ................................................................................... 4
Mandatory signs ....................................................................... 4
Availability................................................................................ 4
Legal guidelines........................................................................ 4
Original user manual................................................................. 4
General
safety guidelines
Usage for the intended purpose ................................................ 5
Usage not for the intended purpose........................................... 5
Selection and qualification of personnel.................................... 5
Warning notice.......................................................................... 6
Safety regulations ..................................................................... 6
Description Design ...................................................................................... 8
Scope of delivery ................................................................................................. 10
Transport and storage ................................................................................................. 10
Mounting ................................................................................................. 11
Commissioning Fitting the grease cartridge ........................................................ 12
Connecting the connection cable............................................... 15
Planning external control with PLC............................................. 16
Bleeding the lubricator.............................................................. 16

Schaeffler Technologies BA 67 3
Page
Operation Operating modes...................................................................... 17
4-pin plug, connector assignment ............................................. 17
Input signals at PIN 2................................................................ 18
Output signals at PIN 4 ............................................................. 25
Troubleshooting and
rectification
................................................................................................ 29
Maintenance ................................................................................................ 30
Cleaning................................................................................... 31
Visual inspection...................................................................... 31
Replacing the cartridge ............................................................. 32
Decommissioning ................................................................................................ 33
Disposal ................................................................................................ 33
Technical data ................................................................................................ 34
EU Declaration of Conformity ................................................................................................ 35

4 BA 67 Schaeffler Technologies
Lubricators CONCEPT4
About the
user manual
This user manual is part of the product:
■ Keep for future reference.
Symbols The warning and hazard symbols are defined in accordance with
ANSI Z535.6-2011.
WARNING
In case of non-compliance, death or serious injury may occur. 
CAUTION
In case of non-compliance, minor or moderate injury may occur. 
NOTICE
In case of non-compliance, damage or malfunctions in the product or
the adjacent construction may occur.

Mandatory signs The mandatory sign is defined in accordance with DIN 4884-2 and
DIN EN ISO 7010.
Availability A current electronic version (.pdf) of this user manual can be found
at http://medien.schaeffler.com.
Use the search term BA 67.
Legal guidelines The information in this manual corresponded to the most recent
status at the close of editing. The illustrations and descriptions
cannot be used as grounds for any claims relating to devices that
have already been delivered. Schaeffler Technologies AG & Co. KG
accepts no liability for any damage or malfunctions if the device or
accessories have been modified or used in an inappropriate manner.
Original user manual The original user manual is taken to be a user manual in the German
language. A user manual in another language is to be taken as a
translation of the original user manual.
Use safety goggles

Schaeffler Technologies BA 67 5
General safety guidelines Any person working with the lubricator must read this chapter and
observe the guidelines.
Usage
for the intended purpose
The intended use of the lubricator is to supply rolling bearings that
are installed in machines with grease. A lubricator may only be used
in accordance with the technical data, see page 34.
Usage
not for the intended purpose
The device may not be used in or on vehicles.
The device may not be used in environments with an explosion risk.
The device must not be converted.
Selection and
qualification of personnel
The device may only be mounted, commissioned, operated and
maintained by qualified personnel. The scope of competence,
area of responsibility and monitoring of personnel must be precisely
regulated by the site operator.
A person defined as qualified personnel:
■ has all the necessary knowledge
■ is aware of all the hazards and safety guidelines
■ has read and understood this user manual.
If personnel do not possess the necessary knowledge,
they must be given the necessary training and instruction.
Upon request, Schaeffler can offer appropriate training
courses.

6 BA 67 Schaeffler Technologies
Lubricators CONCEPT4
Warning notice Prevent any interference in or modifications to the device,
or the addition or removal of components not intended for
the device, as this will compromise occupational safety and
invalidate any warranty claims.
Before mounting the device, check for any external damage.
If damage or some other defect is found, the device must not be
commissioned.
Ensure that any unused outlets on the device remain open.
You may only install the device if you are a qualified electrician.
Ensure that the device is disconnected from the power supply and in
a voltage-free state before carrying out any wiring work and opening
or closing electrical connections.
Carry out the installation in accordance with the national and inter-
national regulations covering the installation of electro-technical
equipment.
You may only operate the device within the limits described
in the technical data. If the device is operated outside these limits,
it may be destroyed.
Always use original replacement parts from
Schaeffler Technologies AG & Co. KG for repairs.
Only dismount the device when it is disconnected from the power
supply and in a voltage-free state.
Wear safety goggles at all times when handling the device.
Safety regulations All important safety specifications are described in the following
sections.
Transport Do not throw the device and avoid exposure to severe shocks.
Storage To avoid promoting corrosion, the following ambient conditions
must be ensured:
■ humidity max. 65%, non-condensing
■ no aggressive chemicals in the environment
■ temperature from +5 °C to +40 °C.
The storage period in an unopened condition is a maximum of
two years.

Schaeffler Technologies BA 67 7
Mounting To avoid condensation, the mounting location must be selected so
that the device is kept away from direct sunlight or direct radiated
heat.
The device may only be mounted and connected by a qualified pro-
fessional in compliance with accident prevention regulations.
Work on electrical devices When making connections to an electrical device, the following must
be observed:
■ connection to the power supply only by qualified electricians
■ correct wiring of the electrical components of the device
■ comparison of the voltage data with the available mains voltage.
Firefighting Extinguish burning grease using approved extinguishing agents
only, such as powder, foam or carbon dioxide. Attempting to
extinguish a grease fire with water will create a life-threatening
darting flame.
Maintenance and repair The device may only be maintained and repaired by a qualified
professional in compliance with accident prevention regulations.
Wear safety goggles at all times when handling the device.
The device must be placed in a voltage-free state before starting
repair work. All maintenance and repair work must be carried out
when the device is completely shut down.
Cleanliness must be ensured during all work performed on the
device and cartridge. The penetration of water, liquids and foreign
bodies into the device and cartridge must be avoided.
Troubleshooting and rectification Troubleshooting and rectification may only be carried out by
qualified professionals and in compliance with accident prevention
regulations. Wear safety goggles at all times when handling the
device.
Disposal Lubricators and lubricant-soaked materials must be disposed of
by environmentally acceptable methods.
Electronic devices must be disposed of in accordance with the
relevant regulations.
Conversion The device must not be converted.
In order to comply with directives on electromagnetic
compatibility (EMC), the electrical installation (cables, shielding)
must not be changed.

8 BA 67 Schaeffler Technologies
Lubricators CONCEPT4
Description The lubricator is suitable for the minimal quantity lubrication of four
lubrication points with grease.
Design The device has a zinc die-cast housing, which contains the micro-
processor-controlled piston pumps and the electronic control unit.
A replaceable grease cartridge is inserted above the piston pumps.
Grease cartridge The grease is supplied in cartridges. A grease cartridge cannot be
refilled. Special empty cartridges are the exception to this.
The responsibility for using reusable empty cartridges and refilling
the cartridges with suitable grease lies with the operator.
Further information Information on suitable accessories can be found in
TPI 252, Lubricators.
 Upper housing part
 Grease cartridge
 Outlets
 Multi-function interface
 Protective cap
Figure 1
Design of lubricator
1
2
4
5
3
0016CE9C0016CE9C

Schaeffler Technologies BA 67 9
Outlets The device has two piston pumps. Each piston pump has two outlets.
Splitters or progressive distributors can be connected to increase
the number of lubrication points to be supplied via the number
of outlets.
Further information Information on suitable accessories can be found in
TPI 252, Lubricators.
Multi-function interface The 4-pin connector with an external thread M12 ⫻ 1 (communication
interface and power supply) is connected to the socket on the
lubricator.
 Outlets of piston pump 1
 Outlets of piston pump 2
Figure 2
Outlets
1
2
2.2
2.1
1.2
1.1
0016CE8D0016CE8D
Figure 3
Multi-function interface
0016CE7E0016CE7E

10 BA 67 Schaeffler Technologies
Lubricators CONCEPT4
Scope of delivery In order to obtain a complete system ready for operation, a lubricant
cartridge and accessories must also be ordered.
Note Only original accessories may be used.
Further information Information on the combination of components required to obtain
a complete system ready for operation, such as lubricant lines,
connection fittings, connection cables and cartridges, can be found
in TPI 252, Lubricators.
Transport and storage The packaging does not protect the product against damage during
transportation.
NOTICE
The electronics and plastic parts may be damaged or destroyed by
strong vibrations. Avoid dropping the device and exposure to severe
shocks.

Ambient conditions To avoid promoting corrosion, the following ambient conditions
must be ensured during storage:
■ humidity max. 65%, non-condensing
■ no aggressive chemicals in the environment
■ temperature from +5 °C to +40 °C.

Schaeffler Technologies BA 67 11
Mounting The illustrated fasteners should be used. The fasteners are not
included in the scope of delivery.
For the dimensions of the device, see page 34.
 Mount the lubricator as close as possible to the lubrication points.
Further information Information on the length of the lubricant lines can be found in
TPI 252, Lubricators.
a = screw retention,
medium strength
Figure 4
Fastening dimensions
243
96
6,6
a
33,5
M6 (DIN 912)
150
100
3030
1.1 1.2 2.1 2.2
0016E2640016E264

12 BA 67 Schaeffler Technologies
Lubricators CONCEPT4
Commissioning During commissioning, the lubricator is filled with lubricant and
bled. The power supply is also available.
NOTICE
Compressed air can damage the seals and introduce contaminants
into the lubricator. Use brushes and cloths to clean the parts.

Fitting the grease cartridge  To fit the grease cartridge, proceed as shown, Figure 5 to Figure 8 ,
page 14.
NOTICE
If contaminants enter the lubricator, the piston pumps will be
damaged. Clean the upper housing part prior to detaching,
if contaminated. 
Figure 5
Detach the upper housing part
0016D6060016D606

Schaeffler Technologies BA 67 13
NOTICE
If contaminants enter the lubricator, the piston pumps will be
damaged. Clean the grease cartridge prior to insertion,
if contaminated. 
Figure 6
Removing the seal
on the grease cartridge
0016D6150016D615
Figure 7
Fitting the grease cartridge
2⫻
0016E0320016E032

14 BA 67 Schaeffler Technologies
NOTICE
If force is used in an attempt to screw the grease cartridge into place
in the wrong position, the lower housing part may become damaged.
Fit the grease cartridge so that the label is aligned centrally with the
outlets and do not use excessive force when screwing the cartridge
into place.

NOTICE
Contaminants can enter the lubricator if the grease cartridge is not
fully screwed into place. Screw-mount the grease cartridge through
two revolutions, to ensure it is seated correctly.

CAUTION
Risk of injury due to parts springing off if the collar ring is not fitted
correctly. The upper housing part is preloaded after mounting.
Rotate the collar ring in a clockwise direction until you feel it click
into place at the end stop.

Figure 8
Fitting and securing
the upper housing part
0016D7F50016D7F5

Schaeffler Technologies BA 67 15
Connecting
the connection cable
The connection cable can transmit the supply voltage and control
signals.
NOTICE
A defective connection cable can damage the device.
Replace a defective connection cable immediately. 
NOTICE
Failure to observe the safety regulations may result in damage
to the device. Ensure that all electrical connection work is carried
out exclusively by qualified personnel who observe the safety
regulations.

NOTICE
Exceeding the permissible connection values will cause serious
damage to the device. Observe the permissible connection values,
see page 34.

Connector assignment
Figure 9
Connecting
the connection cable
BU
WT
DC 24 V +4,8/–4,8 V
BN
BK
GND
1
2
4
1
4
3
2
3
0016D8150016D815
PIN Assignment Colour
1Input voltage DC 24 V +4,8/–4,8 V,
operating voltage stabilised at DC 24 V
Brown (BN)
2Input signals for controlling
the individual pump outputs
White (WT)
3Output, ground (GND) Blue (BU)
4Output signal Black (BK)

16 BA 67 Schaeffler Technologies
Lubricators CONCEPT4
Planning external control
with PLC
The lubricator must be integrated into an external controller (PLC)
for operation. The lubricator dispenses the required lubricant
quantity via various input signals. Remote monitoring is possible as
a function of the output signals for the purpose of querying the fill
level of the cartridge and any error messages.
For further information on the control signals, see page 17.
Bleeding the lubricator  Activate the function FIL via the external controller (PLC) using
the 12-seconds signal.
 The lubricator delivers 20 lubricant doses per outlet.
The total duration for carrying out the function FIL is
approx. 12 minutes per pump body.
NOTICE
Air in the lubricant line can damage the lubrication point due to
insufficient lubrication. Bleed the lubricator every time it is
commissioned.

 Carry out the function FIL for as long as necessary until grease
emerges from the outlets. It may be necessary to carry out
the function FIL several times until lubricant emerges.
For detailed information on the 12-seconds signal (function FIL),
see page 23.

Schaeffler Technologies BA 67 17
Operation
Operating modes The device works with pulse control through the connection of
an external controller (PLC). A corresponding program must be
created in the PLC to operate the lubricator.
An input and an output must be provided on the control side to
integrate the lubricator into an external controller.
Input signals at PIN 2 are transmitted by the controller.
Output signals at PIN 4 can be picked up via HIGH/LOW level
for further processing (for example, indicator lights or external
controller).
NOTICE
Exceeding the output current will cause serious damage to the
device. The maximum permissible output current must not exceed
I
max
⬍ 20 mA. Do not connect an inductive load (for example,
relay).

The lubricator can be switched off completely by shutting off
the supply voltage. Once the supply voltage has been reconnected,
the device carries out an automatic check and works after receiving
an input signal from the PLC.
4-pin plug,
connector assignment
Power is supplied via PIN 1 and PIN 3. The PLC must send a control
signal to PIN 2. The lubricator transmits signals to the PLC via PIN 4.
A signal has one of the following two states:
■ HIGH
■ LOW.

18 BA 67 Schaeffler Technologies
Lubricators CONCEPT4
Connector assignment
Input signals at PIN 2 The input signals trigger the grease dispensing process or are used
to acknowledge error messages. A further input signal can only be
sent after a certain pause time. The lubricator only reacts to control
signals at PIN 2 in certain operating modes. These operating modes
are output via PIN 4 as HIGH/LOW level and must be picked up and
processed on the control side.
Overview of signals
Figure 10
4-pin plug
1
2
4
3
0016E9E40016E9E4
PIN Assignment Colour
1Input voltage DC 24 V +4,8/–4,8 V,
operating voltage stabilised at DC 24 V
Brown (BN)
2Input signals for controlling
the individual pump outputs
White (WT)
3Output, ground (GND) Blue (BU)
4Output signal Black (BK)
Input signal Description of function
2-seconds signal Stroke at pump body 1
5-seconds signal Stroke at pump body 2
8-seconds signal Stroke at pump bodies 1 and 2
12-seconds signal (FIL) Bleed pump, for example at first use
14-seconds signal (CLr) Acknowledge the error message