Wittenstein LUC+125 User manual

Revision: 02
2022-D064493
Operating manual
Lubricator LUC+125

Operating manual Lubricator
Revision: 02 2022-D064493
Revision Date Comment Section
01 26.06.2018 First edition All
02 26.07.2018 Technical data All
Revision history
Sales
WITTENSTEIN alpha GmbH
Walter-Wittenstein-Strasse 1
D-97999 Igersheim
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Service contact
In case you have technical questions, please contact:
WITTENSTEIN alpha GmbH
Customer Service
Walter-Wittenstein-Strasse 1
D-97999 Igersheim
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Copyright
The rights to the layout and corporate design are held by © WITTENSTEIN alpha GmbH 2018
The rights to the contents and texts are held by © DLS Schmiersysteme GmbH 2018
This documentation is protected by copyright.
All rights, including those to the photomechanical reproduction, duplication and distribution by means
of special processes (e.g. data processing, data carriers and data networks), including extracts, are
held by WITTENSTEIN alpha GmbH and DLS Schmiersysteme GmbH.
Subject to technical changes and changes of contents.

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Inhalt
1 About this manual 2
1.1 Signal words 2
1.2 Safety symbols 3
1.3 Layout of the safety instructions 3
1.4 Information symbols 3
2 Safety 4
2.1 EC/EU directive 4
2.2 Hazards 4
2.3 Personnel 4
2.4 Intended use 4
2.5 Reasonably foreseeable misuse 4
2.6 Warranty and liability 5
2.7 General safety instructions 5
3 Functional description 6
3.1 Type plate 7
3.2 Marking 7
3.3 Ordering code 7
3.4 Technical data 8
4 Transport and storage 9
4.1 Scope of delivery 9
4.2 Packaging 9
4.3 Transport 9
4.4 Storage 9
5 Installation 10
5.1 Preparations 10
5.2 Installation and initial operation 10
5.3 Installing the electrical connections 11
6 Operation 12
6.1 Adjustable parameters 12
6.1.1 P (Pressure) 12
6.1.2 t (time / running time, cartridge
emptying times) 12
6.1.3 C (cycle / number of cycles,
strokes per lubrication cycle) 12
6.1.4 Pu (pulse mode) 13
6.1.5 U (cartridge size) 13
6.1.6 E (Error / inversion of
output signals) 13
6.1.7 L (empty signal) 13
6.1.8 F (feedback signal /
motor running check) 13
6.2 Selection of the parameters t and C. 14
6.3 Menu structure 15
6.4 Switching the lubricator on/off 16
6.5 Changing parameters in the
standard menu (Pro) 17
6.6 Triggering a single lubrication sequence 18
6.7 Triggering the filling function
(venting/filling)
19
6.8 Changing parameters in the
Expert menu 20
6.9 Replace the cartridge 22
6.10 Replacing the battery 22
7 Messages and Errors 23
7.1 Pin assignment – time control 23
7.1.1 Overview of ouput signals
(PIN4) – Time control 23
7.1.2 Standby – Time control 24
8 Pulse control 24
8.1 Control signals (PIN 2) 24
8.1.1 Overview of control signals 24
8.1.2 2sec signal (single pump stroke) 25
8.1.3 3sec signal (two pump strokes) 26
8.1.4 4sec signal (C pump strokes) 27
8.1.5 6sec / 12 sec signal
(filling/venting procedure) 28
8.1.6 10sec signal (acknowledge error
message) 29
8.2 Output signals (PIN 4) - Pulse control 30
8.2.1 Overview of output signals 30
8.2.2 Error E1 (empty) 30
8.2.3 Error E2 (no cartridge) 31
8.2.4 Transition of error E1 to E2 31
8.2.5 Error E3 (Low voltage) 32
8.2.6 Error E7 (Excess pressure) 32
9 Maintenance 33
9.1 Maintenance tasks 33
9.1.1 Visual inspection 33
9.1.2 Cleaning 33
9.2 Start up after maintenance 33
9.3 Maintenance schedule 34
9.4 Notes on the lubricant used 34
9.5 Disposal 34
10 Appendix 35
10.1 Tightening torques for common
thread sizes in general
mechanical engineering 35
10.2 Declaration of conformity 36

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1 About this manual
This manual contains the information required to be able to safely use the LUC+125 (FlexxPump 125),
referred to from now on as the lubricator.
Details contained in possibly added supplementary pages (e.g. for special applications) do apply.
Contradictory details in this manual are thus rendered invalid.
In case of questions regarding special applications, please contact WITTENSTEIN alpha GmbH.
The user must ensure that this manual has been read and understood by all persons who are entrusted
with the installation, operation or maintenance of the lubricator.
Store the manual within reach of the lubricator.
Inform your colleagues who work near the machine about the safety instructions so that nobody is
injured.
The original version of this manual was written in German. All other language versions are translations
of this manual.
1.1 Signal words
The following signal words are used to draw your attention to hazards, prohibitions and important infor-
mation:
DANGER
This signal word indicates a directly impending hazard that will result in seri-
ous injuries or even death.
WARNING
This signal word indicates a possibly impending hazard which may result in
serious injuries or even death.
CAUTION
This signal word indicates a possibly impending hazard which may result in
minor to serious injuries.
NOTE
This signal word indicates a possibly impending hazard which may result in
damage to property.
EA note without a signal word indicates application hints or particularly im-
portant information for the handling of the lubricator.

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1.2 Safety symbols
The following safety symbols are used to draw your attention to hazards, prohibitions and important
information:
General danger Electric voltage Flammable
substances
1.3 Layout of the safety instructions
Safety instructions in this manual are laid out according to the following pattern:
CAUTION
Explanatory text indicates the consequences of disregarding the note.
• Instruction text directly indicates what needs to be done.
1.4 Information symbols
The following information symbols are used:
• requests you to take action
indicates the consequences of an action
provides you with additional information on the action

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2 Safety
It is imperative that all persons who work with the lubricator follow this manual, in particular the safety
instructions, as well as the rules and regulations applicable to the place of use.
In addition to the safety instructions shown in this manual, the generally applicable legal and other rules
and regulations for the prevention of accidents (e.g. personal protective equipment) and the protection
of the environment must be obeyed.
2.1 EC/EU directive
Within the scope of the EC/EU directive, initial operation is forbidden until such time as it has been
determined that the machine into which this lubricator is installed conforms to the requirements of this
directive.
An EC/EU declaration of conformity for this lubricator can be found in the appendix
(see section „10.2 Declaration of conformity”).
2.2 Hazards
In order to avoid hazards for the user or damage to the machine, the lubricator may be used only for its
intended use (see section „2.4 Intended use“) and only if it is in perfect working order.
Before commencing work, read the general safety instructions
(see section „2.7 General safety instructions“).
2.3 Personnel
Only qualified personnel who have read and understood this manual may work on the lubricator.
2.4 Intended use
Adhere to the following points in order to use the lubricator as it was intended:
• The lubricator is approved only for industrial use.
• The lubricator may be used only in accordance with the technical data
(see section „3.4 Technical data“).
• Unauthorized structural modifications to the lubricator are not permitted.
• Read the operating manual and act accordingly.
• During the operation of the lubricator a visual inspection of both the lubricator and the lubrication
point is to be carried out regularly. Any abnormalities are to be rectified immediately!
• Cartridge refill is not permitted.
• Use only lubricants that have been approved by the manufacturer.
• Obey the regulations for occupational health and safety and the prevention of accidents.
• Work with and on the lubricator only with the appropriate authorization, see section „2.3 Personnel“.
• All other types of use or the disregard of any of these points are regarded as inappropriate.
In this case no liability can be accepted and/or warranties given.
2.5 Reasonably foreseeable misuse
Any use that extends beyond the maximum permitted technical data is regarded as inappropriate and
is therefore forbidden.

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2.6 Warranty and liability
Warranty and liability claims in the case of personal injuries or damage to property are excluded in the
case of
- disregarding the instructions for transport and storage
- unintended use (misuse)
- maintenance or repair work carried out improperly or not at all
- improper assembly/disassembly or improper operation (e.g. test run without secure
attachment)
- operation of the lubricator with defective protective devices and fixtures
- operation of the lubricator without lubricant
- operation of the lubricator with non-approved lubricant
- operation of the lubricator when it is very dirty
- changes or modifications made without the written consent of
WITTENSTEIN alpha GmbH
2.7 General safety instructions
DANGER
Faulty electrical connections or unapproved conducting components will
result in serious injuries or even death.
• Have all electrical connection work done by qualified personnel only.
• Replace damaged cables or plug connectors immediately.
NOTE
Loose or overloaded screw connections can cause damage to the lubricator.
• Mount and check all screw connections for which tightening torques are
specified using a calibrated torque wrench.
WARNING
Lubricants are combustible.
• Do not use water jets to extinguish fires.
• Suitable extinguishing agents are powder, foam, water mist and carbon dioxide.
• Observe the safety instructions issued by the lubricant manufacturer
(see section “9.4 Notes on the lubricant used”).
CAUTION
Solvents and lubricants can lead to skin irritations.
• Avoid direct skin contact.
Solvents and lubricants can pollute soil and bodies of water.
• Use and dispose of cleaning solvents and lubricants properly.

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3 Functional description
The lubricator has a double-piston pump. The two pistons run in opposite directions, where one piston
draws in the lubricant while the other pumps the quantity drawn in during the previous stroke to the
outlet. 0.15 cm³ of lubricant is pumped per stroke or dosing sequence. The lubricator can be controlled
via an external controller (PLC) - pulse controlled. Alternatively the time and frequency of the lubrication
and the quantity of lubricant per lubrication sequence can be defined via the parameters t and C - time
controlled.
Operating condition and error messages are displayed on the LCD. The conditions and errors can
additionally be read out and interpreted on the external controller.
SET
6
1
2
3
4
5
7
8
9
10
1 LCD
2 Action field
3 Lubricant supply
4 Type plate
5 M5 thread for rear-side mounting
6 Sensor pin for cartridge
7 M12x1 connector
8 Magnetic pin
9 Hydraulic connection / outlet
10 M5 thread for mounting from
underneath

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3.1 Type plate
The type plates of the lubricator are attached to the pump and cartridge.
3.2 Marking
The lubricator is clearly identified by an additional type plate with the serial number. The CE mark is
applied visibly to the type plate.
Manufacturer
DLS Schmiersysteme GmbH
Gewerbering 5
D-82140 Olching
Phone: [phone]
Fax: [phone]
e-mail: [email protected]
www.DLS-Schmiersysteme.de
3.3 Ordering code
LUC
+125 --
05 1105
Type
LUC+=
electromechanical
lubricator
Size
(Volume of lubricant)
125 = 125 cm³
250 = 250 cm³
Lubricant
05 = WITTENSTEIN alpha G11
06 = WITTENSTEIN alpha G12
07 = WITTENSTEIN alpha G13
Number of outlets
1 = 1 pump, 1 outlet
Principle of operation
1 = 24 V, pulse controlled
2 = 24 V, time controlled
3 = battery version, time controlled
4 = battery version, time controlled, pressure relieved 12 bar
Tube length
00 = no tube
02 = 2000 mm
05 = 5000 mm

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3.4 Technical data
Housing
Dimensions with 125 cm³ cartridge
(W x H x D)
83 x 152 x 83 mm
Dimensions with 250 cm³ cartridge
(W x H x D)
83 x 190 x 83 mm
Weight (without lubricant) approx. 350 g
Mounting possibilities Rear side 2 x M5
Underside 1 x M5 and/or G1/4"
Torque M5 3 Nm
Mounting position arbitrary, preferably vertical
Permissible operating temperature -20 °C to +70 °C
Material PA 6.6 GF 30 / POM
Lubricants
Cartridge volume 125 cm³ / 250 cm³
Lubricant type Grease up to NLGI Class 3, solid contents possible
Hydraulic data 24V Version Battery Version
Number of outlets 1 1
Thread of outlet G1/4" and M6 G1/4" and M6
Number of lubrication points up to 4 in conjunction with
splitter
up to 14 in conjunction with
progressive distributor
up to 4 in conjunction with
splitter
up to 10 in conjunction
with progressive distributor
Hydraulic connection Direct or via additional tube
connection to PA tube
Direct or via additional tube
connection to PA tube
Max. pressure 12 or 50 bar (adjustable) 12 or 35 bar (adjustable)
Dosing volume/stroke 0.15 cm³ 0.15cm³
Number of pump strokes per
cartridge
approx. 830 (with 125 cm³) /
approx. 1660 (with 250 cm³)
apprx. 830 (with 125 cm³)
Electrical data 24V Version Battery Version
Display LCD LCD
Operating voltage 24 V DC (external) +/- 5 % 4.5 V
Current input Imax < 300 mA
standby current < 25 mA
-
Fuse 750 mA, slow-blow -
Connecting plug M12x1, 4-pole M12x1, 4-pole
Protection class IP 54 IP54

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4 Transport and storage
4.1 Scope of delivery
• Check the completeness of the delivery against the bill of delivery.
Missing parts or damage must be reported immediately in writing to the freight forwarder, the
insurance company or WITTENSTEIN alpha GmbH.
4.2 Packaging
The lubricator is delivered packed in plastic foil and boxes.
• Dispose of the packaging material at the disposal points provided for the purpose.
Observe the applicable national regulations for disposal.
4.3 Transport
NOTE
Hard knocks such as falling down or being set down too hard can damage
the lubricator.
• Use only lifting and load attachment devices with a sufficient load capacity.
• The permissible lifting weight of a lifting device may not be exceeded.
• Set the lubricator down slowly.
WARNING
Suspended loads can fall down and cause serious injuries or even death.
• Never walk or remain under suspended loads.
4.4 Storage
Store the lubricator in the original packaging in a horizontal position and a dry environment at a tempe-
rature of 0 °C to + 30 °C. Store the lubricator for a maximum of 2 years.
We recommend the “first in – first out” principle for the storage logistics.

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5 Installation
• Before commencing work, read the general safety instructions (see section
2.7 “General safety instructions”).
5.1 Preparations
NOTE
Compressed air can damage the seals of the lubricator.
• Do not use compressed air to clean the lubricator.
5.2 Installation and initial operation
The lubricator is delivered vented with a screwed-on
cartridge and mounting bracket mounted.
Optional:
• Unscrew the cap of the cartridge.
• Screw the cartridge onto the lubricator.
• Mount the lubricator in the desired position
(see section „3.4 Technical data“ for the mounting
specifications).
Mount the supplied tube connector.
Max. tightening torque: 2 Nm.

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• Observe the instructions for safety and use of the thread locking
compound used
Apply a thread-locking compound (e.g. Loctite®243)
to the fastening screws.
• Fasten the lubricator with the pre-mounted hold-
ing bracket in the intended position. Fine adjustment
of the installation height is possible by means of the
slotted holes. The prescribed screw sizes and tighten-
ing torques can be found in Table 2.
Through-holes in the mounting bracket
Type/size Hole spacing
[mm]
Number x
diameter
[ ] x [mm]
For screw size /
property class
Tightening torque
[Nm]
LUC+125
95 2 x 6.6 M6 / 8.8 9.0
LUC+250
Table 2: Through-holes in the mounting bracket
5.3 Installing the electrical connections
DANGER
If touched, live components will lead to electric shocks which can cause
serious injuries or even death.
• Before carrying out electrical installation work, observe the five safety rules of
electrical engineering:
– Switch off.
– Secure against unintentional restart of power.
– Check that no voltage is present.
– Ground and short circuit.
– Cover adjacent and electrically live parts.
• Check whether the protective caps are fitted to the plugs.
Check the plugs for damage and dirt if protective caps are missing.
DANGER
In the presence of moisture electrical work can lead to electric shocks which
can cause serious injuries or even death.
• Carry out the electrical assembly only in dry rooms.

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6 Operation
Depending on the mode (time or pulse mode), the lubricator is operated with the magnetic pin provided
or via an external controller. However, the individual control parameters can subsequently be changed.
6.1 Adjustable parameters
Para-
meter Designation Permissible values
Factory
setting time
control
Factory
setting
pulse control
Change to
P Maximum pressure [bar] 12 / 50 50 50 Expert menu
t Cartridge emptying time
[months]
1 ... 24* ... 36 6 -
Standard
menu and
Expert menu
C Number of cycles
[0.15 cm³/stroke]
1 / 2 / ... / 10 2 1
Pu Pulse mode 0 / 1 0 1
U Cartridge size [x 10 cm³] 12 / 25 12 12
Expert menu
E Inversion of output signals 0 / 1 1 0
L Empty signal 0 / 1 / 2 1 2
F Feedback signal 0 / 1 0 1
* only battery version
6.1.1 P (Pressure)
The parameter P indicates the maximum counter pressure. It can be set to 12 bar, 35 bar (only battery
version) or 50 bar. The maximum pressure of the system may need to be reduced depending on the
system in use and the lines connected (e.g. tubes). If the preset maximum pressure is exceeded, the
lubricator goes into the fault status and stops the current lubrication cycle. A message is displayed on
the LCD and sent to an external controller.
No further pumping sequence takes place until the message has been acknowledged.
6.1.2 t (time / running time, cartridge emptying times)
The parameter t can only be adjusted if the parameter Pu0 is set. With the parameter Pu1 the emptying
time is controlled externally by a controller.
The parameter t indicates the time in which the cartridge should be emptied. The emptying time can be
set from 1 to 36 months (battery version max. 24 months). For further information,
see „6.2 Selection of the parameters t and C.
6.1.3 C (cycle / number of cycles, strokes per lubrication cycle)
The parameter C indicates how many dosing strokes take place per lubrication cycle, or how much
lubricant is supplied. 1 to 10 dosing strokes can be set. With a value of C4, four dosing strokes of
0.15 cm³ each take place.

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6.1.4 Pu (pulse mode)
The parameter Pu indicates the mode in which the lubricator is operating. With Pu1 the dosing is con-
trolled by an external controller. With Pu0 the dosing is controlled by the parameter t.
6.1.5 U (cartridge size)
The parameter U indicates which cartridge size is being used. U12 stands for cartridge size 125 cm³,
U25 for cartridge size 250 cm³.
6.1.6 E (Error / inversion of output signals)
The parameter E indicates whether the signal images to an external controller for empty state, error
message and feedback (motor running check) are generated inversely. For further information, see
section „7.1.1 Overview of ouput signals (PIN4) – Time control“, „8.2 Output signals (PIN 4) - Pulse
control“.
6.1.7 L (empty signal)
The parameter L indicates how the signal image for the empty signal is sent to an external controller.
This parameter is dependent on parameter E.
For the setting E0, only the values L0 (low-level signal) and L2 (rectangular signal) are possible for L.
For the setting E1, only the values L1 (high-level signal) and L2 (rectangular signal) are possible for L.
6.1.8 F (feedback signal / motor running check)
The parameter F indicates whether a signal is sent to an external controller during a pumping sequence
(motor running). This parameter is dependent on parameter E.
For the setting E0 the lubricator sends a low-level signal to an external controller during the
pumping stroke; the pumping stroke cannot be recognized in the controller.
For the setting E1 the lubricator sends a high-level signal to an external controller during the pumping
stroke; the pumping stroke is registered.

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6.2 Selection of the parameters t and C.
NOTE
The emptying time t can only be set on the lubricator when it is not controlled by an
external controller (Pu0).
Emptying time t for 125 cm³ cartridge (U12)
t (months) 1 3 6 10 12 15 20 24 30 36
Lubricating quantity per month [cm³] 125 41.6 20.8 12.5 10.4 8.3 6.3 5.2 4.2 3.5
Emptying time t for 250 cm³ cartridge (U25)
t (months) 1 3 6 10 12 15 20 24 30 36
Lubricating quantity per month [cm³] 250 83.3 41.6 25 20.8 16.7 12.5 10.4 8.3 6.9
Values for t are examples; values from 1 to 36 (24 V version) / 1- 24 (battery version) can be set.
Number of cycles C, strokes per cycle
C 12345678910
Lubricating quantity per cycle [cm³] 0.15 0.30 0.45 0.60 0.75 0.90 1.05 1.20 1.35 1.50
The emptying time t specifies the period over which the entire quantity of lubricant is supplied per car-
tridge. Correspondingly, it also defines how much lubricant is supplied per month.
The number of cycles C indicates how many strokes take place per lubrication and thus how much
lubricant is supplied per lubrication.
The time between two lubrications (dwell time) can be determined with the following equation:
Tdwell = t x 720 h x C / H
With t in hours and H as the total number of strokes per cartridge (830 with a 125 cm³ cartridge), the
dwell time for a lubricating quantity of 0.60 cm³ (C4) over six months is calculated below:
Tdwell = 6 x 720 h x 4 / 830 = 20.9 h
The result of the calculation is a lubrication cycle of 21 hours. 0.60 cm³ of lubricant are supplied every
21 hours over a period of six months.

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6.3 Menu structure
The following illustration shows the complete menu structure of the lubricator.
MAX1
MAX1 MAX2 MAX1 MAX2MAX1
3x 7x
Action by user,
LED flashes red once
Lubricator is ready for operation, but is
not switched on
Sequence / reaction in menu Lubricator is in operation
LED on LCD flashes green Lubricator is waiting for a signal from
the external controller
LED on LCD flashes red Carry out a single dosing stroke
LCD display flashes twice Programming
Firmware information Expert menu
Programming (Standard menu)
Expert menu

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6.4 Switching the lubricator on/off
3x
Switching on
1. Hold the magnetic pin against the action field.
The LED flashes three times red.
2. Remove the magnetic pin when the display indicates ON.
3. The firmware information and the settings for Emptying time (t) and Number of cycles (C)
are displayed.
On flashes twice on the LCD
The green LED flashes; the lubricator is in operation.
The lubricator discharges lubricant in accordance with the presets for t and C.
If the LCD displays PAU, the lubricator is not receiving a control signal from an external controller.
Switching off
1. Hold the magnetic pin against the action field.
The LED flashes red and run, On and OFF are displayed in succession on the LCD.
2. Remove the magnetic pin when the display indicates OFF.
OFF flashes twice on the LCD.
The lubricator is switched off.

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6.5 Changing parameters in the standard menu (Pro)
The following parameters can be set in the standard menu:
Pulse mode Pu
Emptying time t
Number of cycles C
A description of the individual parameters can be found in section “6.1 Adjustable parameters”.
NOTE
The emptying time t can only be set on the lubricator when it is not controlled by an
external controller (Pu0 / time controlled).
Changing parameters
aLubricator in operation (PAU / On)
1. Hold the magnetic pin against the action field.
The LED flashes red and run, On, OFF, On and Pro are displayed in succession on the LCD.
2. Remove the magnetic pin when the display indicates Pro.
The display shows the parameters Pu, tand Cin succession (depending on the lubricator type).
3. When the parameter to be set is displayed, hold the magnetic pin against the action field.
On the LCD the value for the parameter is incremented and starts again from the beginning
after reaching the highest value.
4. Remove the magnetic pin from the action field when the desired value is displayed.
The set value flashes twice.
The next parameter is displayed on the LCD.
After the last parameter the lubricator returns to operation again automatically.

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6.6 Triggering a single lubrication sequence
You can trigger a single lubrication sequence at any time during operation with the lubricator.
MAX1
aLubricator in operation (PAU / On)
1. Hold the magnetic pin against the action field.
The LED flashes red.
2. Remove the magnetic pin when the display indicates run.
The lubricator performs a single lubrication sequence.
The LCD displays the approximate counter pressure and the pumping piston.
On completion of the lubrication sequence the lubricator returns automatically to operation.