Lubricator

LUC+125, battery version, time-controlled
Operating manual

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Sales department
WITTENSTEIN alpha GmbH
Walter-Wittenstein-Straße 1D-97999 Igersheim
Germany

Customer Service department
In the event of technical questions, contact the following address:

Copyright© WITTENSTEIN alpha GmbH 2023 reserves all rights for layout and corporate design.
© TriboServ GmbH & Co. KG 2023 reserves all rights for content and text.
This documentation is protected by copyright.
WITTENSTEIN alpha GmbH and TriboServ GmbH & Co. KG reserve all rights to photomechanical reproduction, copying, and the distribution by special processes (such as computers,
file media, data networks), in whole or in part.
Subject to technical and content changes without notice.

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Table of contents
1

2

3

4

5

6

About this manual .............................................................................................................................3
1.1

Information symbols and cross references ...................................................................................3

1.2

Scope of delivery ..........................................................................................................................3

Safety ..................................................................................................................................................3
2.1

EC/EU Directive ............................................................................................................................3

2.2

Personnel .....................................................................................................................................3

2.3

Intended use .................................................................................................................................4

2.4

Reasonably foreseeable misuse ..................................................................................................4

2.5

Guarantee and liability ..................................................................................................................4

2.6

General safety instructions ...........................................................................................................5

2.7

Structure of warning instructions ..................................................................................................5

2.7.1

Safety symbols ......................................................................................................................5

2.7.2

Signal words ..........................................................................................................................6

Description of the lubricator .............................................................................................................7
3.1

Overview of lubricator components ..............................................................................................7

3.2

Name plate and labeling ...............................................................................................................7

3.3

Marking .........................................................................................................................................8

3.4

Ordering codes .............................................................................................................................8

3.5

Dimensions ...................................................................................................................................8

3.6

Scope of delivery ..........................................................................................................................8

3.7

Technical data ..............................................................................................................................9

3.8

Lubricants ...................................................................................................................................10

3.9

Cord lengths ...............................................................................................................................10

Transport and storage .....................................................................................................................10
4.1

Transport ....................................................................................................................................10

4.2

Storage .......................................................................................................................................10

Assembly ..........................................................................................................................................11
5.1

Preparations ...............................................................................................................................11

5.2

Mounting the lubricator ...............................................................................................................11

5.3

Connecting the prefilled hose .....................................................................................................12

5.4

Electrical interface connection ....................................................................................................12Startup and operation .....................................................................................................................13
6.1

Operation and settings ...............................................................................................................13

6.1.1

General ................................................................................................................................13

6.1.2

Factory settings ...................................................................................................................13

6.1.3

Actions with magnetic pen ...................................................................................................14

6.2

Menu and display messages ......................................................................................................14

6.3

Selection of parameters t and c ..................................................................................................16

6.3.1
6.4

Menu structure ....................................................................................................................17

Error messages ..........................................................................................................................18

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6.5

Switching the lubricator on/off .................................................................................................... 20

6.6

Parameter change in standard menu (Pro)................................................................................ 20

6.7

Triggering single lubrication cycle .............................................................................................. 21

6.8

Triggering the filling function (venting/filling) .............................................................................. 21

6.9

Changing parameters in the "Advanced programming" menu ................................................... 22

7

Output signals – Time control ....................................................................................................... 23
7.1

Connection assignment – Time control...................................................................................... 23

7.2

Output signals / Display messages – Time control .................................................................... 23

7.3

Standard output signals at PIN 4 – Time control ....................................................................... 24

8

7.3.1

Empty cartridge signal ........................................................................................................ 24

7.3.2

High-signal output (+24 V) at PIN 4 .................................................................................... 24

7.3.3

Low-signal output (0 V) at PIN 4 ......................................................................................... 24

Maintenance and disposal ............................................................................................................. 25
8.1

Maintenance schedule ............................................................................................................... 25

8.1.1

Visual inspection ................................................................................................................. 25

8.1.2

Cleaning ............................................................................................................................. 25

8.1.3

Changing the cartridge and battery .................................................................................... 26

8.2

Recommissioning ...................................................................................................................... 28

8.3

Disposal ..................................................................................................................................... 28

9

Appendix .......................................................................................................................................... 29
9.1

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EC/EU declaration of conformity ................................................................................................ 29

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1

About this manualThis manual contains information which is necessary for the safe use of the LUC+125(FlexxPump1 - B), battery version (time-controlled), hereinafter referred to as lubricator.
If this manual is supplied with amendment sheets (e.g. for special applications), then theinformation in the amendment is valid. Contradictory specifications in this manual are therefore
void.
The user should contact WITTENSTEIN alpha GmbH with any questions about special
applications. The actual operator must guarantee and ensure that this manual including any
amendments are read and understood by all persons assigned to install, operate, or maintain the
lubricator. For this reason, keep this manual in a suitable and ideally accessible location near the
lubricator.
Inform colleagues who work in the area around the machine about the safety instructions so thatno one sustains injuries.
The original was written in German, all other language versions are translations of the original
manual.

1.1

Information symbols and cross references
The following information symbols are used:• Indicates an action to be performed
 Indicates the results of an action
 Provides additional handling information
A cross reference refers to the chapter number and the header of the target section (e.g.
2.3 "Intended use").
A cross reference to a table refers to the table number (e.g. Table "Tbl - 1").

1.2

Scope of delivery• Check the completeness of the delivery against the delivery note.
 Immediately notify the carrier, the insurance company, or WITTENSTEIN alpha GmbH in
writing of any missing parts or damage.

2

SafetyThis manual, especially the safety instructions and the rules and regulations valid for theoperating site, must be observed by all persons working with the lubricator. General legal rules
and regulations as well as applicable rules and regulations on prevention of accidents [e.g.
personal protective equipment (PPE)] and environmental protection must be observed.

2.1

EC/EU Directive
In scope of the EC/EU Directive, commissioning (recommissioning) of a machine at which the
lubricator was installed and/or attached is prohibited until it is verified that the machine complies
with all provisions of the applicable regulation.
An EC/EU declaration of conformity for this lubricator can be found in the appendix (seechapter 9.1 "EC/EU declaration of conformity").

2.2

Personnel
Only technicians who have read and understood this operating manual may perform work on the
lubricator. Local and/or company regulations apply accordingly.

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2.3

Intended use
For the intended use of the lubricator, the following points must be observed:- The lubricator is approved only for industrial applications.
- The lubricator may only be put into operation according to the technical specifications (seechapter 3.7 "Technical data").
- Unauthorized modifications to the lubricator are not permitted.
- Read and observe the operating manual.
- During operation of the lubricator, regular visual inspections must be carried out at the
lubricator itself as well as the lubrication point. Any irregularities and their cause must be
corrected immediately.
- The cartridge must not be refilled.
- The lubricator must not be opened or dismantled.
- Only lubricants which are approved by WITTENSTEIN alpha GmbH may be used.
- Applicable rules and regulations on occupational safety, prevention of accidents andenvironmental protection must be observed.
- Any works or tasks with or at the lubricator may only be carried out with authorization (seechapter 2.2 "Personnel").
Any use other than the previously described intended use or non-compliance with one of thepoints specified above is regarded misuse. In this case no liability or warranty claims will beassumed.

2.4

Reasonably foreseeable misuse
Any usage of the lubricator that exceeds the maximum permitted technical data is consideredmisuse and is therefore prohibited.

2.5

Guarantee and liability
Any guarantee and liability claims are excluded for personal injury and/or material damage incase of:- Ignoring the information on transport and storage;- Misuse;- Improper or not carried out maintenance and repair;- Incorrect assembly / disassembly or incorrect operation;- Operation of the lubricator when safety devices and equipment are defective;- Operation of the lubricator without lubricant;- Operation of the lubricator with non-approved lubricant;- Operation of a heavily contaminated lubricator;- Modifications or changes without written approval by WITTENSTEIN alpha GmbH;- Opening and/or partly or complete dismantling of the lubricator.

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2.6

General safety instructions
The operation of the lubricator involves remaining risks even when adhering to the intended use.
Defective or faulty electrical connections or unapproved, current-carrying components cancause serious injuries and even death.
• Have all electrical connection work performed by qualified technicians only.
• Immediately replace damaged cords or plugs.
Loose or overtightened screw connections can cause damage to the lubricator:
Mount and check all screw connections according to the specified admissible tightening
torques. Use a calibrated torque wrench.
Lubricants are flammable, can cause skin irritation, and can contaminate soil and water:
•

•
•
•
•
•

2.7

In case of fire, do not use a jet of water to extinguish.
In case of fire, only use suitable extinguishing agents such as powder, foam or carbon
dioxide.
Always observe the applicable safety instructions by the lubricant manufacturer on the safety
data sheet of the used lubricant.
Use protective gloves to avoid direct skin contact with lubricants.
Use and dispose of lubricants properly.

Structure of warning instructions
B

A

C
2.7.1

D

Warning instructions are situation-specific. They will
be precisely where tasks are described in which
dangers can arise.
The warning instructions in this manual aredesigned according to the following pattern:
A = safety symbol
B = signal word
C = Type and consequence of the danger
D = Avoiding the danger

Safety symbols
The following safety symbols are used to indicate hazards, prohibitions and important
information:

General danger

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2.7.2

Signal words

DANGER
This signal word indicates an imminent danger that will cause
serious injuries or even death.

WARNING
This signal word indicates a potential hazard that could cause
serious injuries and even death.

CAUTION
This signal word indicates a potential hazard that could cause minor
or serious injuries.

NOTICE
This signal word indicates a potential hazard that could lead toproperty damage.

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3

Description of the lubricator
The lubricator is designed as a highly compact double piston pump for grease as lubricant. The
two pistons run force-controlled and in opposing directions. They are both connected to the sameoutlet. The outlet is secured by an integrated check valve. At each dispensing cycle , approx.
0.15 cm³ of lubricant are dispensed. Multiple subsequent dispensing processes can be set.
The lubricator features an electrical interface. The included magnetic pen allows for the
lubrication amount dispensed per time to be adjusted or set to ensure ideal supply of lubricant to
the lubrication point.
The different operating states are displayed at the front as well as other additional information(e.g. empty cartridge, errors).
The power supply is established via a replaceable battery. The lubricator can be switched on/off
via the M12x1 interface. An external power supply can also be used to transmit information about
an empty cartridge as well as error messages, e.g. to an external control system.
We recommend the battery-powered lubricator exclusively for stand-alone lubrication points
which do not have to be monitored externally or which may not be supplied with external power.
Owing to its increased operational reliability and the expanded settings options for emitting
signals, the 24V-DC version is the better choice in terms of technology and economic efficiency, if
information about an empty cartridge and error messages are to be transmitted to a control
system (e.g. PLC). You can obtain further information about an existing product fromWITTENSTEIN alpha GmbH directly.

3.1

Overview of lubricator components

1

2

8
9
7
10
6

4
5

3

Pos.

Designation1

LUC+125, battery version, time-controlled

2

Exchange cartridge LUE+125

3

Assembly bracket

4Interface M12x1, 4-pole

5Magnetic pen (in holder)6

Hose connection

7

Action field

8

Display

9

Name plate10

CE symbol-

Battery

Tbl - 1 Overview of lubricator components

3.2

Name plate and labelingB

A
Mat-No: xxxxxxxx
LUC+125-xxxx-xx

Pos.

Designation

A

Material number

B

Ordering codes (see chapter 3.4 "Ordering codes")Tbl - 2 Name plate

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3.3

Marking
The CE mark is attached to the lubricator housing. The position of the CE mark is described inchapter 3.1 "Overview of lubricator components".
Manufacturer
TriboServ GmbH & Co. KG
Gelthari-Ring 397505 Geldersheim, Germany
Tel.: +49-(0)9721-47396-60
Fax: +49-(0)9721-47396-69
E-mail: info@triboserv.de
www.triboserv.de

3.4

Ordering codes

3.5

Dimensions
Dimensions can be found- in our catalog,- under www.wittenstein-alpha.de.
CAD data and dimension sheets are available upon request.

3.6

Scope of delivery
The lubricator is available in different versions. They can be distinguished by the execution, thelubricant filling as well as the included accessories.

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3.7

Technical data
Housing
Dimensions without cartridge

83 x 96 x 85 (W x H x D)

mm

Dimensions with cartridge 125 cm383 x 154 x 85 (W x H x D)

mm

Weight (without cartridge)

approx. 350g

Assembly option

Assembly bracket with slottedholes pre-assembled.
Bottom side: IG M5 (3 Nm)

Mounting position

vertically

Housing material

PA 6.6 GF30 / POM

Outlet material

Stainless steel

Operating temperature *0 ... +60

°C

Lubricant and hydraulics
Cartridge volume

125

Lubricant properties

Grease up to NLGI, class 2

No. of outlets

1

Hydraulic connection

PA hoseMax. pressure

50 (-10%/+15%)

bar

Dispensed volume

Per stroke 0.15 (-5%)

cm3

cm3

Electrics
Display

Display

Operating voltage (DC)

4.5

V

Operating voltage (DC) of external statusmonitoring

24 (20V...28V)

V

Fuse protection

0.75 (slow)

A

Protection class

IP 54

Power consumption

Imax < 0.3

Ibias < 0.025

A

For further information on the electrical system, see chapter 7 "Output signals – Time control"!
* Depending on the lubricant used
Tbl - 3 Technical data

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3.8

Lubricants
Only use lubricants approved by WITTENSTEIN alpha GmbH in dedicated original cartridges
exclusively developed for the lubricator.
The lubricants used depend on the individual application. The
respective designation can be found on the label of the cartridge.
For further information about lubricants, documentation and safety data sheets, please contact
WITTENSTEIN alpha GmbH directly.

3.9

Cord lengths
In general, the lubricator should be installed as closely as possible to the device to be supplied(lubrication point). Ideally, this should be directly at the lubrication point. If this is not possible due
to space restrictions or reasons regarding accessibility, cords can be used between the lubricatorand the lubrication point (e.g. distribution).
The maximum hose length depends on the temperature as well as the used grease, hoses andaccessories.

4

Transport and storage
The lubricator is delivered in an outer packaging (cardboard box) and with a lubricant cartridge
and other accessories in the same shipment. For protection against humidity and dirt, it isadditionally packaged in PE foil. To prevent leakage of the prefilled lubricant from the lubricator,
protective caps are installed at the lubricant inlet and outlet.
Dispose of the packaging materials at the recycling sites designated for this purpose incompliance with applicable national and operational regulations.
After receipt of the lubricator, check the completeness of the delivery against the delivery note.
Immediately notify the carrier, the insurance company, or WITTENSTEIN alpha GmbH in writingof any potentially missing parts or damage.

4.1

Transport

NOTICE
Hard shocks, for instance because of falling or hard dropping, candamage the lubricator.
•

4.2

Do not throw the lubricator.

Storage
Store the lubricator in its original packaging in vertical position under dry, frost-protectedconditions at an ambient temperature of +5°C to +30°C. The maximum unopened storage time is
1 year.
For storage logistics, the "First-In-First-Out principle" (FiFo) is recommended.

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5

Assembly
The lubricator is delivered with an inserted lubricant cartridge in vented condition as a ready-toinstall component with an installed assembly bracket. The outlet is sealed with a yellow cap.
The provided hose lines have already been prefilled with the respective lubricant.

5.1

Preparations

NOTICE
Among other things, compressed air can lead to damage to the sealsof the lubricator and to contamination of the lubricator or lubricant bydirt and particles.
Do not use compressed air.
Make sure that the assembly location is not considerably
contaminated.

•
•

5.2

Mounting the lubricator•

Observe the safety and processing instructions for the threadlocker
to be used.
Apply threadlocker (e.g. LOCTITE® 243) to thefastening screws [K].
• Install the lubricator with the pre-assembled
assembly brackets [3] at the intended position.
The slotted holes enable fine adjustment of theinstallation height.
 The prescribed screw sizes and tightening
torques can be found in the table "Tbl".
•

K
3

Hole spacing[mm]

Quantity x diameter[ ] x [mm]For screw size /property class

Tightening torque
[Nm]

95

2 x 6.6

M6 / 8.8

9.0

Tbl - 4 Through-holes in assembly bracket

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5.3

Connecting the prefilled hose••Remove the yellow closing cap.
Screw in the provided hose connection [6].
 Max. tightening torque 2 Nm.

Establish the hydraulic connection between the
distributor and the lubricator [6]. Ensure that
hoses and connection elements are tight andproperly assembled.
 If possible, use the prefilled hoses included in
the scope of delivery with the respective
lubricant!
•6 Further important instructions on how to connect the hose can be found in the separate
manual "Prefilled high pressure hose" (doc. no. 2098-D072334). The manual is included in
the scope of delivery of the hose or is available on request from WITTENSTEIN alphaGmbH. Always state the material number when doing so.

5.4

Electrical interface connection

DANGER
Defective or faulty electrical connections or unapproved, currentcarrying components can cause serious injuries and even death.
•••

Have all electrical connection work performed by qualified technicians
only.
Immediately replace damaged cords or plugs.
Observe the five safety rules of electrical engineering before starting
electrical installation work:- Switch off the power supply.
- Secure against unintended reactivation.
- Check that there is no voltage.
- Ground and short-circuit.
- Cover adjacent and electrified parts.

The following work steps must only be carried out if you- wish to switch the lubricator on and off externally.
- wish to retrieve error messages.
Connect the lubricator [1] to the external power
supply or control system with a suitableconnection cord [J] via the M12x1 interface [4]at the bottom of the lubricator.
 Further information can be found in chapter 6.5"Switching the lubricator on/off".
 Depending on the application, connection cords
with straight or angled socket can be used.
 For the properties of the connection cord,
please refer to chapter 7.1 "Connection
assignment – Time control".
•

1

4
J

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6

Startup and operation••

Read the general safety instructions before beginning to work (see chapter 2.6 "Generalsafety instructions").
Make sure that the lubricator is properly and fully assembled. In particular, the power supply
must be connected, and a lubricant cartridge must be attached.

6.1

Operation and settings

6.1.1

GeneralWhat you should know about operation and setting of the lubricator:- The lubricator is designed as an individual lubricator for one lubrication point.
- The lubricator is time-controlled and works time-based via the integrated microelectronics.
Power is supplied from a battery. The lubricator cyclically delivers a defined amount of
lubricant from the cartridge to the outlet.
- The re-lubrication amount is defined in months by the emptying time setting of the cartridge.
Discharge times t of 1...24 month(s) and a number of cycles c of 1…10 can be set.
- The single-use changeable cartridges with a lubricant capacity of 125 cm3 ensure controlled
and consistent quality of lubricants and are filled without any trapped air. The lubricator offersa reliable supply to lubrication points and prevents downtime of machinery. This version of the
lubricator is designed for grease lubricants.
- The lubricator can be used without an external 24 V DC power supply. The lubricant cartridge
is included in the scope of delivery and already installed in the lubricator.
- To call up the empty cartridge message or error messages, an external 24V-DC power supply
is required.
- The respective conditions of the lubricator are shown on the display, which also enables
recognition of the status by LEDs in different colors.
- In case of any questions regarding your applications and the correct settings for the lubricator,
please contact WITTENSTEIN alpha GmbH.

6.1.2

Factory settings
Parameter
Program menu

Designation

Factory settings

Resultt

Emptying time6

6 monthsc

Number of cycles

2

2 pump strokes per
lubrication(0.15 cm3 / stroke)P

Maximum pressure

35

35 bar

The parameter P may only be changed after consultation.
If you have any questions, please contact
WITTENSTEIN alpha GmbH Sales / Customer Service.
Tbl - 5 Factory settings

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6.1.3

Actions with magnetic pen
The magnetic pen attached to the bottom of the lubricator allows to perform actions and changesof settings on the lubricator. This magnetic pen can be easily and safely stored permanently
under the lubricator.
Remove the magnetic pen [5] from the bottomof the lubricator.
 The magnetic pen is permanently held
magnetically in the receptacle on the bottom.
Simply pull it out.
•

5
Guide the magnetic pen [5] onto the action field
SET [7] at the front of the lubricator.
 As soon as the magnetic pen is recognized by
the lubricator when placed on the action field
SET, the red LED lights up in the display. The
menu changes at 2 second intervalls.
•

7

Remove the magnetic pen from the action field
SET when the desired menu item is shown on
the display.
 The red LED is turned off. You have performed
an action. The display flashes 2x briefly together
with the green LED.
•

5

•

6.2

After having performed the desired action or settings, insert the magnetic pen back into thereceptacle provided on the bottom of the lubricator.

Menu and display messages
The display of the lubricator is used to show various kinds of information to the user.
SymbolDesignation

NoticeDisplay information

The display visually shows information
both during operation and forprogramming.

Tbl - 6 Display information

Display

Assignment
Top LED: red
Bottom LED: green
Tbl - 7 LED assignment

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Information in
display

Meaning

See chapter

No display

Battery not connected; battery completely empty

6.1

OFF

Lubricator switched off

6.5

ON

Lubricator switched on and ready for use

6.5

PRO

PRO menu

6.6

c1 ... 10

Adjustable setting of the number of cycles c

01 ... 24

Adjustable setting of the discharge time c

RUN

RUN menu
01 … 35

FIL

During the manually triggered active runcommand, the display shows the approximate
counterpressure in bar. In addition, the green
LED lights up.
FIL menu

01...35

During the manually triggered active FIL
command, the display shows the approximate
counterpressure in bar. In addition, the green
LED lights up.

Clr

If the process is canceled during the FIL
command, Clr is displayed.

INF

6.7

INF menu
A90

Firmware version of the lubricator

r01

Firmware version of the lubricatort06

Currently set value of the discharge time t

c02

Currently set value of the number of cycles c

P35

Currently set maximum pressure P

6.8

6.9

E1

Error E1 (empty cartridge)

6.4

E2

Error E2 (cartridge error / no cartridge fitted)

6.4

E3

Error E3 (undervoltage)

6.4

E4/E5

Error E4/E5 (fatal error)

6.4

E7

Error E7 (overload)

6.4

01 … 35

After each cycle, the maximum applied counterpressureduring the cycle is displayed in bar.
Tbl - 8 Display messages

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6.3

Selection of parameters t and c
Discharge time t
Month

1

3

6

10

12

15

20

24

Lubrication volume permonth 125 (U12) [cm3]

125

41.6

20.8

12.5

10.4

8.3

6.3

5.2

Tbl - 9 Discharge time t for cartridge

Values for t are exemplary, values from 1 - 24 (24 V version) can be set.
Number of cycles c

1

2

3

4

5

6

7

8

9

10

Lubrication volume per
cycle [cm3]

0.15

0.3

0.45

0.6

0.75

0.9

1.05 1.20 1.35

1.5

Tbl - 10 Number of cycles c, strokes per cycle

The discharge time t sets the period over which the total volume of lubricant per cartridge isdelivered. Accordingly, this also determines how much lubricant is supplied per month.
The number of cycles c indicates how many strokes are performed per lubrication process andhow much lubricant is supplied per lubrication process.
The time between two lubrication process (pause time) can be determined with the following
formula:TPause = t x 720 h x c / H
Using t in hours and H as the number of total strokes per cartridge (830, for cartridge 125 cm³)and a lubrication volume of 0.60 cm³ (c4) over 6 months, the following pause time is obtained as
an example:
TPause = 6 x 720 h x 4 / 830 = 20.9 h
For above parameters t and c, the lubrication cycle is 21 hours. A lubrication volume of 0.60 cm³
is dispensed every 21 hours over a period of six months.

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6.3.1

Menu structure
The following figure illustrates the complete menu structure of the lubricator.

10x

1 MAX

1 MAX

SymbolDesignation

2 MAX

Symbol

1 MAX

2 MAX

1 MAX

Designation

Action by user, LED flashes
red once

Lubricator is ready for operation
but not switched on

Action by user, LED flashes
red several times

Lubricator is in operation

Sequence/reaction in menu

Perform individual manual
dosing operation

LED in display flashes green

Programming

LED in display flashes red

Extended programming (onlyafter consultation)

Indicator in display flashes 2x

Advanced programming

Firmware information

Lubricator is switched on via an
external switch

Programming(Standard menu)

Lubricator is switched off via an
external switch

Tbl - 11 Menu structure

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6.4

Error messages
The status is permanently monitored by the microelectronics integrated in the lubricator. In caseof any irregularities, an addressed error message is issued and shown on the display. The red
LED flashes every 5 seconds to visually indicate an error.
Display

Fault

Explanation

E1

Cartridge empty

E2

Cartridge error;
cartridge notrecognized orincorrectly fitted

E3

Battery very low

RemedyPlace a new cartridge on the
lubricator (see chapter 8.1.3"Changing the cartridge andbattery").
 No need to acknowledge theerror; it is automatically cleared
after the corrective action is
performed.

•

•
•

•

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Switch the lubricator off (OFF).
Replace the battery along withthe cartridge (see chapter
8.1.3 "Changing the cartridgeand battery").
Switch the lubricator on (ON).

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Display

Fault

Explanation

RemedyE4/E5

Fatal error

The error E4/E5 can have different
causes:•The motor is taking too long
because the ambient
temperature is too low. Checkthe temperature and adjust thisif necessary.

Switch the lubricator off (OFF)and on again (ON).
Important! Between switching the
lubricator off and on, 60 seconds
must elapse.
- Battery very low, hence motor
runtime too long
•

•
•

•

E7

Overload; thecounterpressure
at the lubrication
point is too highSwitch the lubricator off (OFF).
Replace the battery along withthe cartridge (see chapter
8.1.3 "Changing the cartridgeand battery").
Switch the lubricator on (ON).

•

If the error E4 / E5 still
persists, remove the lubricatorfrom the application and return
it with the lubricant cartridge
and a description of the error
to WITTENSTEIN alphaGmbH for investigation.

•

Check the lubrication point andeliminate the cause.
Switch the lubricator off (OFF)and on again (On).

•Tbl - 12 Malfunctions

 If the lubricator is connected to an external control system (PLC), for instance, when an error
occurs, the differentiated error messages are sent to the PLC for errors E1 ... E7 as output
signals via PIN 4 of the electrical interface of the lubricator (see chapter 7.2 "Output signals /Display messages – Time control ").

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6.5

Switching the lubricator on/off
To switch on the lubricator, PIN 2 and PIN 3 must be connected to each other at connection
M12x1 (see chapter 7.1 "Connection assignment – Time control"). This can either be done
permanently by inserting a bridge or made switchable by connecting it with a potential-free limit
switch – maximum cable length 5 m.
Switching on
Switch on the lubricator by completing theconnection between PIN 2 and PIN 3.
 When switched on, the settings for discharge
time t and number of cycles c are displayed.
 The lubricator then switches to the ON display.
 The green LED flashes, the lubricator is inoperation.
Lubricant dispension is carried out by the lubricatoraccording to the presettings for t and c.
Switching off•

Switch off the lubricator by breaking theconnection between PIN 2 and PIN 3.
 OFF is shown on the display.
 The lubricator is switched off.
•

6.6

Parameter change in standard menu (Pro)
Settings for discharge time and number of cycles
The following parameters can be set in the standard menu:- Discharge time t- Number of cycles c A description of the individual parameters can be found in chapter 6.1.2 "Factory settings".
Changing parameters Lubricator in operation (On).
• Hold the magnetic pen against the action field.
 The LED flashes red and the display shows run, On,
Pro in sequence.
• Remove the magnetic pen when Pro is displayed.
 The display shows (depending on the lubricatortype) the parameters t and c one after the other.
Hold the magnetic pen against the action field when
you see the parameter to be set.
 In the display, the value for the parameter iscounted up and starts again from the beginning after
the highest value.
•

When the desired value is reached, remove themagnetic pen from the action field.
 The set value flashes twice. The display shows thenext parameter.
 After the last parameter, the lubricator automatically
returns to operation.
•

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6.7

Triggering single lubrication cycle
The lubricator can be used to trigger a single lubrication cycle at any time during operation.
 Lubricator in operation (On)• Hold the magnetic pen against the action field.
 The LED flashes red.
Remove the magnetic pen when run isdisplayed.
 The lubricator performs a single lubrication
cycle.
 The display shows the approximate
counterpressure and the delivering pump piston.
 After the lubrication cycle is finished, thelubricator automatically returns to operation.
•

1 MAX

6.8

Triggering the filling function (venting/filling)
The lubricator is delivered with an assembled cartridge, vented and with a pre-assembled
mounting bracket.
For venting or filling of the lubrication point, the filling function of the lubricator can be triggered.
The lubricator then automatically performs 40 delivery cycles with a total lubrication volume of
6 cm³. The filling function can be canceled manually.
 Lubricator in operation (On)• Hold the magnetic pen against the action field.
 The LED flashes red and the display shows run,On, Pro, On, FIL in sequence.
Remove the magnetic pen when FIL isdisplayed.
 The lubricator starts the filling process. The
display shows the approximate counterpressure
and the delivering pump piston.
 After the lubrication cycle is finished, thelubricator automatically returns to operation.
•

1 MAX

2 MAX

1 MAX

2 MAX

1 MAX

Canceling the filling process• During the filling function, hold the magnetic pen against the action field.
 The display shows Clr.
• Remove the magnetic pen.
 The filling function is canceled. The lubricator automatically goes into operation.

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6.9

Changing parameters in the "Advanced programming" menu

NOTICE
Changes in the menu can fundamentally affect the operation of the
lubricator.
•

Only change any advanced programming parameters if you are awareof the effects.

The following parameters can be set in the "Advanced programming" menu:- Discharge time t- Number of cycles c- Pressure P A description of the individual parameters can be found in chapter 6.1.2 "Factory settings".
10x
 Lubricator switched off (OFF)• Hold the magnetic pen against the action field.
 The LED flashes red ten times, then the display
shows EP.
Remove the magnetic pen when EP isdisplayed.
 The display shows the first parameter that canbe changed.
•

Hold the magnetic pen against the action field tochange the parameter.
 In the display, the value for the parameter iscounted up and starts again from the beginning
after the highest value.
•

When the desired value is reached, remove themagnetic pen from the action field.
 The set value flashes twice. The display shows
the next parameter. If the parameter is notchanged, the current value flashes twice.
 After the last parameter, the lubricator is
automatically switched off (OFF).
•

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7

Output signals – Time control
The lubricator operates in time control mode as a time-based and cycle-controlled lubrication
system according to the values set in the PRO menu.

7.1

Connection assignment – Time control

2

3

PIN

Assignment

Color

1

+24 V DC (for status monitoring)

Brown

2

Input ON/OFF

White

3

Output ON/OFF (GND)

Blue

4

Output signal – Status monitoringBlack

Type: M12x1 plug socket; 4-pin, A-coded

1

4

Tbl - 13 PIN assignment – Time control

The lubricator can be put into standby when switched off in time control mode. The time until theplanned next lubrication cycle having passed before switching off the lubricator is automaticallysaved by the lubricator in the integrated microelectronics. After the restart, the lubricator
continues to operate according to the set values.
 After a longer standstill of the lubricator, manual triggering of a lubrication pulse isrecommended (see chapter 6.7 "Triggering single lubrication cycle").
 The output signal at PIN 4 can be used for further processing (e.g. indicator light or external
control system). The maximum admissible output current of Imax < 20 mA must not be
exceeded. Inductive loads (e.g. relays) must not be connected!

7.2

Output signals / Display messages – Time control
Display

Designation

Output signal (PIN 4)

See chapter

OFF

Switched off

Low, permanent

6.1

On

Ready

Low, permanent

7

E1

Empty cartridge

High, permanent

7.3.2

E2

Cartridge error

High, permanent

7.3.3

E3

Undervoltage

High, permanent

7.3.2

E4/E5

Fatal error

High, permanent

7.3.2

E7

Overload/overpressure

High, permanent

7.3.2

Tbl - 14 Display messages at factory settings

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7.3

Standard output signals at PIN 4 – Time control
In the time control mode, the lubricator provides the output signals via the electrical interface. For
this purpose, the lubricator must be supplied externally with 24V DC. This also enables remotestatus control, in addition to the visual indication at the display and LED on the lubricator.
Generally the output signals can only be scanned and must not be subject to inductive loads. The
maximum output current of Imax < 20 mA must also be considered.

7.3.1

7.3.2

Empty cartridge signal
The integrated microelectronics of the lubricator is equipped with an automatic counter, whichcounts the number of delivery operations after fitting a new and full cartridge. For a cartridge with
125 cm3 of lubricant, the number of strokes is 780. The low calculative difference serves asprotection against the ingress of air into the hydraulic system. This ensures that the empty
cartridge message (error E1) is sent in time [e.g. to the external control system (PLC)]. Therefor ahigh output signal can be easily, quickly and reliably recognized by the external control system.
An inversion of the output signals is not possible.
High-signal output (+24 V) at PIN 4
A permanent and continuous high signal (+24 V) at
PIN 4 indicates that there is one active error.
The lubricator does not operate according to thesettings made and does not deliver lubricant fromthe cartridge to the outlet.

7.3.3

Low-signal output (0 V) at PIN 4
A permanent and continuous low signal (0 V) at PIN
4 indicates that there is no active error.
The lubricator operates according to the settings
made and delivers lubricant from the cartridge tothe outlet.

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8

Maintenance and disposal
•
•

8.1

Before carrying out any maintenance or work, please note the general safety instructions (seechapter 2 "Safety") and observe all applicable local and operational safety regulations.
Do not disable any protective device without authorization!

Maintenance schedule
The following maintenance schedule for the lubricator must be observed:
MaintenanceCommissioning

After 500 hours orafter 3 months

Annually

If
necessary

Visual inspection

x

x

x

x*

Cleaning

x

x

x

x*

Changing the
cartridge/battery

x**

x***

x*

*
**
***

Depending on application conditions and lubricant consumption
Depending on the delivery condition (ordered version)
Recommended after 2 years at the latest
Tbl - 15 Maintenance schedule.

8.1.1

Visual inspection
•
•
•
•
•

8.1.2

Check the entire lubrication system (lubricator and any connected accessories including
cords, hoses and distributiors) by careful visual inspection for external damage (e.g. loose
connections).
Check the condition of the lubrication point for correct lubricant supply.
Replace damaged or defective parts immediately to ensure a continuous and permanent
lubrication.
Check the fill level in the cartridge on the lubricator.
Check any error messages at the lubricator and correct the causes respectively.
Cleaning•

Clean the lubricator by suitable means (e.g. absorbent cloths) to remove dirt.

NOTICE
Among other things, compressed air can lead to damage to the sealsof the lubricator and to contamination of the lubricator or lubricant bydirt and particles.
•

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Do not use compressed air for cleaning the lubricator.

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8.1.3

Changing the cartridge and battery

NOTICE
Already opened lubricant cartridges must not be reattached to the
lubricator, as the integrated stroke counter is automatically reset
after a cartridge is removed.
•

Always use full lubricant cartridges.

Only use original lubricant cartridges with lubricants approved by
WITTENSTEIN alpha GmbH.
•

Observe the maximum storage time of lubricants filled in cartridges.

Refilling of empty or open lubricant cartridges is not possible.
Make sure that the same lubricant is used in the new cartridge as
already used before. Make sure that only cartridges with the same
capacity are used.
•

Compare the specifications on the lubricant cartridge.

The battery of the lubricator must be replaced at the same time as
the lubricant cartridge.
•

Observe the battery safety instructions.

The following table indicates the available lubricant cartridges and the replacement battery:
Designation

LubricantCapacity

Material number

LUE+125-05-1

WITTENSTEIN alpha G11

125 cm3

20068231

LUE+125-06-1

WITTENSTEIN alpha G12

125 cm3

20068233

LUE+125-07-1

WITTENSTEIN alpha G13

125 cm3

20068236

LUE+125-00-1

Klüber Microlube GB0

125 cm3

20068238

Battery LUC+125--

20068247

Tbl - 16 Exchange cartridges.

Changing lubricant cartridges is easy and only requires two steps.
The cartridge and battery only need to be changed if the cartridge is empty, the battery is empty,
or if the useful life of the lubricant was exceeded. Cartridges and batteries can be changed during
normal operation of the lubricator. Besides changing the cartridge and battery, no additional
measures are necessary!
 A malfunction has occurred at the lubricator (error E1, E3); the red LED flashes every 5
seconds to visually indicate an error.
OR The battery of the lubricator is completely empty, the display is dark (OFF is not shown).

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Unscrew the empty cartridge of the lubricator.

2

1

L

•

Turn the empty cartridge [2] counter-clockwise
to remove it from the lubricator [1] and disposeof it in compliance with applicable regulations.

 Ensure that the work is carried out under clean
conditions. Dirt and particles must not enter the
lubricant inlet. If necessary, clean before you
start working (chapter 8.1.2 "Cleaning").

Remove the empty battery.
••M

Pull the empty battery [L] out of the battery compartment[M] with the battery cable.
Release the polarity-protected connection and properly
dispose of the empty battery after completing the work.

Inserting the new battery
Wait at least 60 seconds before inserting the new battery!
Connect the new battery [L] to the battery cable via thepolarity-protected connector.
• Place the battery and battery cable into the battery
compartment [M].
 Ensure that the battery cable or connector do not protrude
out of the battery compartment.
•

Connection of the new lubricant cartridge

2••

Set the full lubricant cartridge [2] on the
lubricator [1].
Turn the lubricant cartridge clockwise to tighten
it to the lubricator.

1

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2 The final position is reached after two full turns
when the label of the lubricant cartridge [2] isaligned flush with the front cover [8] of the
lubricator.

8

 If error E1 was shown on the display before the cartridge and battery were changed, thedisplay expires and the red LED flashes every 5 seconds. Separate acknowledgment is not
required. The green LED flashes briefly every 5 seconds.
 After completion, the lubricator automatically returns to the last active mode (On/OFF).
 If the empty cartridge (error E1) occurred during a dispensing cycle (delivery), it isautomatically interrupted and continued after the work is completed.

8.2

Recommissioning
•
•

8.3

Reinstall all safeguards and make sure that all tools have been removed from the hazard
area.
Make sure that the lubricator is activated.

Disposal••

For disposal of the lubricator as well as any empty or opened cartridges, applicable national
regulations must be observed.
For disposal, the respective safety data sheets and disposal instructions for the individualcomponents must be observed.

 Refilling of empty lubricant cartridges is not possible.
 Recharging of batteries is not possible.

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9

Appendix

9.1

EC/EU declaration of conformity

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Revision history
Revision

Date

Comment

Chapter

01

03/17/2022

New version

All

02

09/01/2023

Manufacturer

All

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