Lubricator
LUC+400
Operating manual

MN 20059597

2022-D047797

Revision: 05

Operating manual

Lubricator

Revision history
Revision

Date

Comment

Chapter

01

26/06/2018

New Version

All

02

26/07/2018

Technical data

All

03
04
05

30/07/2019
21/04/2021
14/08/2023

Signal duration
Complete revision
Manufacturer

8.1.1
All
All

Sales department
WITTENSTEIN alpha GmbH
Walter-Wittenstein-Straße 1D-97999 Igersheim
Tel.:
Fax:
Email:+49-(0)7931-493-0+49-(0)7931-493-10942
info-alpha@wittenstein.de

Service contact
In the event of technical questions, contact the following address:
WITTENSTEIN alpha GmbH
Customer Service
Walter-Wittenstein-Straße 1D-97999 Igersheim
Tel.:
Fax:
Email:+49 7931 493-10900+49 7931 493-10903
service-alpha@wittenstein.de

Copyright© WITTENSTEIN alpha GmbH 2023 reserves all rights for layout and corporate design.
© TriboServ GmbH & Co. KG 2023 reserves all rights for content and texts.
This documentation is copyright protected.
WITTENSTEIN alpha GmbH and TriboServ GmbH & Co. KG reserve all rights to photo-mechanicalreproduction, 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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Lubricator

Contents
1.
General information about thisoperating manual

1.1
1.2
1.3
1.4

2.

2.1
2.2
2.3
2.4
2.5
2.6
2.7

3.

3.1
3.2
3.3
3.4
3.5
3.6
3.7

4.

4.1
4.2
4.3

5.

5.1
5.2
5.3
5.4
5.5

6.

6.1
6.2
6.3

7.

7.1

8.

8.1
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.3
en-1

8.3.1
8.3.2
2 8.3.3
2 8.3.4

Signal words
Safety symbols
Structure of the safety information
Information symbols
Safety
EC/EU Directive
Hazards
Personnel
Reasonably foreseeable misuse
Intended use
Guarantee and liability
General safety instructions
Function description
General information
Name plateMarkingOrdering codes
Dimensions
Scope of delivery
Technical data
Transport and storage
PackagingTransport
Storage
Variants
LUC+400, 1 pump body, 1 outlet(ordering code: LUC+400-xx11-xx)
LUC+400, 1 pump body, 2 outlets(ordering code: LUC+400-xx21-xx)
LUC+400, 2 pump bodies, 2 outlets(ordering code: LUC+400-xx51-xx)
LUC+400, 2 pump bodies, 3 outlets(ordering code: LUC+400-xx31-xx)
LUC+400, 2 pump bodies, 2 outlets(ordering code: LUC+400-xx41-xx)
AssemblyPreparations
Assembly
Commissioning
Operation and control
General information

Input and output signals –external control system (PLC)

3 9.
3 9.1
3 9.1.1
4 9.1.2
4 9.1.3
4 9.2
4 9.3
4 9.4
5 9.5
5 9.6

Empty cartridge
Overload error
Undervoltage/overvoltage error
Fatal error
Maintenance and disposal
Maintenance schedule
Visual inspection
Cleaning
Recommissioning
Cartridge changeDisposalLubricants
Line lengths
EC/EU declaration of conformity

27
29
30
31

32

32
32
33
33
34
37
38
38
39

6

7

7
8
8
9
9
9
10

11

11
11
11

12
12
12
13
13
14

15
15
15
17

18
18

Pin assignment –external control system (PLC)
Input signals –external control system (PLC)
2-seconds control signal
5-seconds control signal
8-seconds control signal
12-seconds control signal
14-seconds control signal
Output signals – external control system (PLC)

19
19
20
20
22
23
24
26
27

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Lubricator

1.

Operating manual

General information about this operating manualThis operating manual contains necessary information to safely operate the LUC+400(FlexxPump4 - D), referred to as lubricator in the following.
If this manual is supplied with amendment sheets (e.g. for special applications), thenthe information 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 and effective operator must guarantee and ensure that this manual including
any amendments are read through by all persons assigned to install, operate, or
maintain the lubricator, and that they fully comprehend them. For this reason, keep thismanual 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 that no one sustains injuries.
The original manual was prepared in German, all other language versions aretranslations of the original instructions.

1.1

Signal words
The following signal words are used in this manual to indicate potential hazards, things
that are forbidden and important information:
DANGER

This signal word indicates an imminent danger that will cause
serious injuries or even death if not avoided.

WARNING

This signal word indicates a potential hazard that could cause
serious injuries and even death if not avoided.

CAUTION

This signal word indicates a potential hazard that could cause minor
or serious injuries if not avoided.

NOTICE

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

INFOThis signal word indicates practical application tips or especially
important information for handling the lubricator.

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1.2

Operating manual

Safety symbols
The following safety symbols are used in this manual to indicate hazards, things thatare forbidden and important information:

General danger

1.3

Electric voltage

Substances that
represent a fire risk

Structure of the safety information
The safety information in this operating manual are structured as follows:

CAUTION
The text explains the consequences of disregarding thisinformation.

§	The text uses direct address to provide instructions about what
to do.

1.4

Information symbols
The following information symbols are used in the text and instructions in this manual:Prompts an action

ÜIndicates the results of an actionProvides additional information about the action

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2.

Operating manual

SafetyThis manual, especially the safety instructions and the rules and regulations valid forthe operating site, must be observed by all persons working with the lubricator. General
legal rules and regulations as well as applicable rules and regulations on preventionof 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 themachine complies with all provisions of the applicable regulation. An EC/EU declarationof conformity for this lubricator can be found in the appendix (chapter 9.6).

2.2

Hazards
To avoid danger to the operator or damage to the machine, at which the lubricator isused, the lubricator may be put to use only for its intended use (chapter 2.5) and ina technically flawless and safe state.
Always read the general safety instructions before beginning work (chapter 2.7).

2.3

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

2.4

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

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2.5

Operating manual

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 technicalspecifications (chapter 3.7).
+ 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 theircause must be corrected immediately.
+ The cartridge must not be refilled.
+ The lubricator must not be opened or dismantled.
+ Only lubricants which are approved by the manufacturer may be used.
+ Applicable rules and regulations on occupational safety, prevention of accidents
and environmental protection must be observed.
+ Any works or activities with or at the lubricator may only be carried out withauthorization (chapter 2.3).
Any use other than the previously described intended use or non-compliance with oneof the points specified above is regarded misuse. In this case no liability or warranty
claims will be assumed.

2.6

Guarantee and liability
Any guarantee and liability claims are excluded for personal injury and/or material
damage in case 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 polluted lubricator;+ Modifications or changes without written approval by WITTENSTEIN alphaGmbH.
+ Opening and/or partly or complete dismantling of the lubricator.

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2.7

Operating manual

General safety instructions
The following safety instructions apply for the lubricator:

DANGER
Defective or faulty electrical connections or unapproved,
current-carrying components can cause serious injuries andeven death.
§ Have all electrical connection work performed by qualified
technicians only.
§ Immediately replace damaged cables or plugs.

NOTICE
Loose or overloaded screw connections can damage thelubricator.
§	Mount and check all screw connections according to thespecified admissible torques.
Use the calibrated torque wrench.

WARNING
Lubricants are flammable.
§	In case of fire, do not use a jet of water to extinguish.
§	In case of fire, only use suitable extinguishing agents like
powder, foam or carbon dioxide.
§	Always observe the applicable safety instructions by the
lubricant manufacturer on the safety data sheet of the usedlubricant.

CAUTION
Lubricants can cause skin irritations.
§ Avoid direct skin contact.

NOTICE
Lubricants can pollute soil and water.
§ Use and dispose of lubricants properly.

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3.

Operating manual

Function description

3.1

General information

The lubricator is designed as a highly compact piston pump for grease as lubricant.
The pistons run with forced-control and in opposed directions. The lubricator isavailable as a version with one lubricant outlet as well as with two, three or four
lubricant outlets, see chapter 5. The outlets are secured by integrated check valves.
At each dispensing process, approx. 0.15 cm³ of lubricant are conveyed.
This lubricator must be integrated in an external control system (e.g. PLC).
The lubricator features an electrical interface for control. By means of output signals,
the lubricator also enables remote monitoring for querying of the status and any
potential error messages (e.g. empty cartridge). The lubricator is controlled via various
input signals processed by microelectronics to ensure ideal supply of lubricants tolubrication points.

7

0

2

3

1
5
8

6
4

Fig. 1 Overview of the lubricator
No.
0
1
2
3
4
5
6
7
8

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Designation						Lubricator
Lubricant outlet or outlets (different variants possible)
Retaining ring
Top part
M12x1 interface
Name plate
Through hole for assembly
Lubricant inlet with thread for cartridge
CE mark2022-D047797

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Lubricator

3.2

Operating manual

Name plate
The name plate is attached to the lubricator housing. The position of the name plate is
described in chapter 3.1, fig. 1.

A

B
i=

xxxxxxx xxx
Mat. No.: 23456789
SN:
1234567
Lubrication: xxx

xx

DMF: 06/20
Made in Germany

WITTENSTEIN alpha GmbH-Walter-Wittenstein-Str.1-97999 Igersheim

D

3.3

E

F

H

Code: xxxC

GA

Designation
Ordering codes (see chapter 3.4)

B

+24 V DCC

Input signal PLC
LubricatorD

Ground (GND)

E

Lubricator output signal

F

Date of manufactureG

Data matrix code (optional)

Marking
The CE mark is attached to the lubricator housing. The position of the CE mark is
described in chapter 3.1, fig. 1.
Manufacturer
TriboServ GmbH & Co. KG
Gelthari-Ring 3
D-97505 Geldersheim
Tel.: +49-(0)9721-47396-60
Fax: +49-(0)9721-47396-69
Email: info@triboserv.de
www.triboserv.de

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3.4

Operating manual

Ordering codes
LUC+ 400-05 1 1-05
Hose length per connection
02 = 2000 mm
05 = 5000 mm

Version
LUC+ = Electro-mechanicallubricator,
complete set

Functional system
1 = Standard

Size (lubricant volume)
400 = 400 cm³

Pump variants
1 = 1 pump, 1 outlet
2 = 1 pump, 2 outlet
3 = 2 pumps, 3 outlets
4 = 2 pumps, 4 outlets
5 = 2 pumps, 2 outlets

Lubricant05 = WITTENSTEIN alpha G11
06 = WITTENSTEIN alpha G12
07 = WITTENSTEIN alpha G13

3.5

Dimensions
Dimensions can be found– in our catalog,– under www.wittenstein-alpha.de.

3.6

Scope of delivery
The lubricator is available in different versions. They can be distinguished by generalfeatures, the number and type of lubricant outlets as well as the included accessories.

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Operating manual

Technical data

Housing
Dimensions without top part

111 x 56.5 x 108 (W x H x D)

Dimensions with top part for 400ml
Cartridge

111 x 198.5 x 108 (W x H x D)

mm

Weight (without cartridge)

1190

g

approx.

Assembly option

Through bore for M6 screw

Mounting position

Any for grease, vertical for oil variant

Housing material

Die-cast zinc / PA 6.6 GF30 / POM

Outlet material

Nickel-plated brass

Operating temperature-10 ... +60°

°C

Cartridge volume

400

cm3

Lubricant properties

Grease up to NLGI, class 2

No. of outlets

1/2/3/4

Hydraulic connection

Via PA hose

Number of lubrication points per outlet

Up to 10 in connection with
progressive distributor*

Max. pressure

70 (-10%/+15%)

bar

Max. continuous operating pressure

70

bar

Conveyed volume

0.15

cm³

Lubricant and hydraulics

per stroke

Electrics
Display

Not available

Operating voltage

24 (20V...28V)

Fuses

0.75 (slow)

Protection class

IP 54

Power consumption

Imax < 0.3

V DCA

Ibias < 0.025

A

For further information on electrics, please refer to chapters 7 or 8!

* The specified value depends on the actual application and may deviate considerably in individual
cases depending on the used lubricant and other conditions.
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4.

Operating manual

Transport and storage

4.1

Packaging

The lubricator is delivered in outer packaging (cardboard box) and – depending on thescope of delivery, with a lubricant cartridge and other accessories – in the same bundle.
For protection against humidity and dirt, these are additionally packaged in PE foil.
Dispose of the packaging materials at the recycling sites intended for this purpose incompliance with applicable national and operational regulations.
After receipt of the lubricator, check the completeness of the delivery against thedelivery note.
Immediately notify the carrier, the insurance company, or WITTENSTEIN alpha GmbHin writing of any potentially missing parts or damage.
4.2

Transport

NOTICE
Hard knocks, for instance because of falling or hard dropping,can damage the lubricator.
§ Do not throw the lubricator.

4.3

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 2 years.
For storage logistics, the "First-In-First-Out principle" (FiFo) is recommended.

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Operating manual

Variants
The lubricator serves as small central lubrication system for supply of one or several
lubrication points. Depending on the actual application case, the lubricator can also be
used for reliable and clean lubrication supply to a few more lubrication points. Parts ofthe system accessories of the manufacturer (e.g. splitters, progressive distributions or
lubrication gears) can be connected to the lubricator to extend the number of supplied
lubrication points over the number of outlets. The lubricator is available as variants
with one or with two pump bodies (PB). The outlets of pump body 1 are marked on the
housing with 1.1 and 1.2, the outlets of pump body 2 with 2.1 and 2.2.

5.1

LUC+400, 1 pump body, 1 outlet (ordering code: LUC+400-xx11-xx)
At the lubricator LUC+400-xx11-xx, the theoretical twooutlets of the installed pump body are internally combined.
With each stroke, the outlet is supplied with 0.15 cm³ of
lubricant.
Number of pump bodies

1

No. of outlets

1

Lubrication volume
differences per pump body

5.2

Not applicable, as only one
pump body

LUC+400, 1 pump body, 2 outlets (ordering code: LUC+400-xx21-xx)
At the lubricator LUC+400-xx21-xx, two outlets are suppliedwith identical volumes of lubricants. With each stroke, one
outlet is supplied with 0.15 cm³ of lubricant. The outlets are
successively supplied with lubricant.
Number of pump bodies
1
No. of outlets
Lubrication volume differences per pump body

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5.3

Operating manual

LUC+400, 2 pump bodies, 2 outlets (ordering code: LUC+400-xx51-xx)
At the lubricator LUC+400-xx51-xx , the theoretical twooutlets per installed pump body are internally combined.
With each stroke, one outlet is supplied with 0.15 cm³of lubricant. The outlets are successively supplied withlubricant.
By individual control of both pump bodies, the lubricator
enables setting of dosing volume differences at outlet 1.1 tooutlet 2.1. An explanation of the different control signals canbe found in chapter 8.2.
Number of pump bodies

2

No. of outlets

2

Lubrication volume differences per pump body
5.4

Yes

LUC+400, 2 pump bodies, 3 outlets (ordering code: LUC+400-xx31-xx)
At the lubricator LUC+400-xx31-xx, the theoretical twooutlets of the first pump body are internally combined in one
outlet 1.1. With each stroke, one outlet is supplied with 0.15
cm³ of lubricant. The outlets are successively supplied withlubricant.
By individual control of both pump bodies, the lubricator
enables setting of dosing volume differences at outlet 1.1 tooutlets 2.1 and 2.2. An explanation of the different control
signals can be found in chapter 8.2.
 At even activation of both pump bodies, outlet 1.1 issupplied with twice the lubricant volume of outlets 2.1 or
2.2 due to the internal combination of the outlets of the firstpump body.
Number of pump bodies

2

No. of outlets

3

Lubrication volume differences
per pump body

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5.5

Operating manual

LUC+400, 2 pump bodies, 2 outlets (ordering code: LUC+400-xx41-xx)
At the lubricator LUC+400-xx41-xx , every possible outlet issupplied separately. With each stroke, one outlet is suppliedwith 0.15 cm³ of lubricant. The outlets are successively
supplied with lubricant.
By individual control of both pump bodies, the lubricator
enables setting of dosing volume differences at outlets 1.1
and 1.2 to outlets 2.1 and 2.2. An explanation of the different
control signals can be found in chapter 8.2.
Number of pump bodies

2

No. of outlets

4

Lubrication volume differences
per pump body

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6.

Operating manual

Assembly

6.1

Preparations
Before beginning to work, inform yourself about the lubricator by reading this operating
manual and particularly the general safety instructions (chapter 2.7). Thoroughly
prepare the assembly location.

NOTICE
Among other things, compressed air can lead to damage to theseals of the lubricator and to contamination of the lubricator or
lubricant by dirt and particles.
§ Do not use compressed air.
§	Make sure that the assembly location is not considerably contaminated.
6.2

Assembly
Electrical interface connection
 Connect the lubricator with a suitableconnection cable and via the M12x1
interface at the bottom of the lubricator
to the external voltage supply or control
system.
 Depending on the application, connection
cables with straight or angled socket can beused.
 For the properties of the connection
cable, please refer to chapter 8.1.

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Operating manual

DANGER
Defective or faulty electrical connections or unapproved,
current-carrying components can cause serious injuries andeven death.
§	Have all electrical connection work performed by qualified
technicians only.
§	Immediately replace damaged cables or plugs.
§	Observe the five safety rules of electrical engineering before
starting electrical installation work:- Switch off the power supply- Secure against unintended reactivation- Ensure that there is no voltage- Ground and short-circuit- Cover neighboring and electrified parts

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6.3

Operating manual

Commissioning
The lubricator is delivered with an inserted cartridge in vented condition as a ready-toinstall component. Yellow hose fittings have been inserted in the outlets.
The provided hose lines have already been prefilled with the respective lubricant.
Carefully assemble the lubricator according to the steps described in chapter 6.2. For
initial commissioning, the following steps may be required depending on the scope ofdelivery:
1. Mechanical attachment
Mechanically attach the lubricator with the through holes at the housing. Observe thepermissible maximum tightening torques!
2. Electrical connection
Connect the lubricator via the M12x1 interface and a suitable cable to the external
voltage supply or external control system (PLC). The lubricator is now activated.
3. Checking the assembly
Make sure that the lubricator is properly and fully assembled. Particularly the voltage
supply must be ensured, and a lubricant cartridge be attached.
4. 12-seconds signal execution
 Not required if lubricators are delivered with the cartridge inserted.
Execute the 12-seconds signal. The detailed description can be found in chapter 8.2.4.
Afterwards, the lubricator executes a specific number of strokes to convey the lubricant
from the cartridge to the outlet.
5. Hydraulic connection
Hydraulically connect the device to be supplied to the lubricator via the provided
prefilled hoses. Ensure that lines and connection elements are tight and properly
assembled.
 If possible, use lines prefilled with the respective lubricant!
6. Checking the settings at the lubricator
Check the basic settings at the lubricator with the values required for the lubrication
point and adjust as necessary. Any changes must be made in the PLC program.

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7.

Operating manual

Operation and control

7.1

General information

What you should know about operation and control of the lubricator:
D F
 or operation and control, the lubricator must be integrated into a control system(PLC), see chapters 7 and 8.
D T
 he single-use changeable cartridges with a lubricant capacity of 400ml ensure
controlled and stable quality of lubricants and are filled without any trapped air.
The lubricator offers reliable supply to lubrication points and prevents downtime
of machinery. This version of the lubricator is designed exclusively for greaselubricants.
D T
 his version of the lubricator cannot be used without lubricant cartridge.
Depending on the ordered version, the cartridge may already be included in thescope of delivery and connected to or inserted in the lubricator.
D In case of any questions regarding your applications and the correct settings forthe lubricator, please contact WITTENSTEIN alpha GmbH.
D F
 or operation and control, the lubricator must be integrated into a control system(PLC). Depending on the signals received from the external control system(PLC), one or several strokes are executed by the lubricator to dispense lubricant(0.15 cm³ per stroke). Depending on the internal condition of the lubricator (e.g.
empty cartridge), different output signals are provided by the lubricator.
 Make sure that your PLC program is suitable for your application and that the
lubrication point is supplied with the correct volume of lubricants per time unit.
If this is the case, the lubricator can be used.
If this is not the case, adjust your PLC program accordingly.
 To use the lubricator, it must first be properly assembled and installed, andafterwards activated. Assembly is very easy and described in detail in chapter 6.2.
 For special versions of the lubricator, the dedicated instructions and information on
the provided note must be observed!

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8.

Operating manual

Input and output signals – external control system (PLC)
The lubricator only works as pulse-controlled lubrication system if unchangeable input
signals (high-level) are transmitted in a defined order from the PLC to the lubricator
via PIN 2. Via high/low-level signals picked up at PIN 4, the lubricator indicates therespective status to the PLC and enables comprehensive control and differentiatedevaluation of the different conditions by suitable programming of the PLC. For
incorporation of the lubricator into an external control system, one input and one output
must be provided on the control side.

8.1

Pin assignment – external control system (PLC)

3

4

2

1

Pin assignment – external control
system (PLC)PIN AssignmentColor
1+24 V DC

Brown

2

Input signal PLC of the
lubricator

White

3

Ground (GND)

Blue

4

Lubricator output signal

Black

Type: M12x1 plug socket; 4-pin
A-codedFor electrical connection to the external control system (PLC) of a system, thelubricator is equipped with a 4-pin plug socket in the form of a connector with standard
M12x1 port.
 The lubricator can be fully shut down by disconnecting the supply voltage. After
reconnection of the supply voltage, the lubricator executes a self-test and resumes its
function after receipt of an input signal from the PLC.
 For operation of the lubricator via an external control system (PLC), a program
corresponding to the communication protocol must be prepared in the PLC.
 The output signal at PIN 4 can be picked up for further processing (e.g. indicatorlight or external control system). A maximum admissible output current of Imax < 20mA
must not be exceeded. Inductive loads (e.g. relays) must not be connected!
 After extended standstill of the lubricator, the "quick check" should be carried out
manually. To do so, execute a specific number of dispensing processes via the PLC(chapter 8.2).

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8.2

Operating manual

Input signals – external control system (PLC)
The lubricator provides the following unchangeable defined control signals (input
signals), which must be transmitted by the PLC to the lubricator via PIN 2 of theelectrical M12x1 interface as high-level signal (+24 V DC).
The control signals must be generated by the external control system (PLC) as highlevel signal (+24V) via specific times, each with a tolerance of +/- 0.1s

Signal duration inseconds

Designation

2 high2-seconds signal

1 stroke PB1

8.2.1

5 high5-seconds signal

1 stroke PB2

8.2.2

8 high8-seconds signal

1 stroke PB1 and
PB2

8.2.3

12 high

12-seconds signal

FIL function

8.2.4

14 high

14-seconds signal

Error acknowledgment

8.2.5

Function

DetailChapter The input signals which can be processed by the lubricator depend on its design.
Compare the lubricator with the different designs described in chapter 5 to identify
the relevant signals to be used for control of the lubricator. The designation of yourlubricator can be found on the name plate attached to the side, see chapter 3.2, fig. 1.
 The lubricator only processes the control signals specified in the table up toa maximum length of 14 seconds. In case of a high-level signal (+24 V DC) outsideof the tolerance, there is no reaction from the lubricator. In case of a high-level signal(+24 V DC) for more than 15 seconds at PIN2 of the electrical interface, there is noreaction from the lubricator.
8.2.1

2-seconds control signal

The 2-seconds control signal triggers one single dispensing process at pump body 1.
After a specific pause time, this control signal can be repeated, or a different control
signal can be transmitted.
The lubricator reacts to control signals at PIN 2 only in a specific operating status.
The operating statuses are transmitted by the lubricator via PIN 4 as high-/low-levelsignal and must be picked up and processed accordingly in the PLC.

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Description:
D The lubricator is properly connectedboth to an external control system via theelectrical interface and to the voltage supply.

U
24V
PIN 2

0V

 The lubricator sends a permanent output
signal (high-level) to PIN 4 indicating
readiness to the external control systemt(PLC). This output signal must be activeo.E.
permanently and without interruption for>3 seconds. Only if this condition is met,
activation by an external control system ispossible.
 The 2-seconds control signal with a highlevel signal duration of 2 (1.9 ... 2.1) seconds
can be sent to the lubricator from the external
control system (PLC).

2s
Tp >22s

U
24V
PIN 4

0V

Tp:
MR:

>3s

<7 ML >17 s

Pause time
Motor run

>3s

t

o.E.

 Directly after release of the signal the motor run (MR) of the lubricator is started and0.15 cm³ of lubricant is conveyed to the outlet. At the same time as the start of motor run(MR), a low-level output signal is sent for confirmation by the lubricator to the external control
system (PLC) for the duration of the motor run (MR).
 The motor runtime (MR) depends on various conditions like the counter-pressureestablished or present in the hydraulic system and the temperature. The motor runtime (MR)of the lubricator is 7...17 seconds.
 After completion of a faultless and successful motor run (MR), the output signal to the
lubricator changes from a low-level to a high-level signal.
 Not before >3 seconds after the end of the faultless and successful motor run, the next
control signal can be sent by the external control system (PLC). In the meantime, thelubricator does not process any control signals.
 To ensure reliable and clear recognition of the control signal, a pause time must be
observed. For the 2-seconds control signal, a pause time (Tp) of at least 22 seconds applies
for the lubricator between two identical or different control signals.
 If an error is recognized by the integrated microelectronics of the lubricator during or
directly after the end of a motor run (MR), this fault is transmitted to the external control
system (PLC) by means of a respective output signal (chapter 8.3).

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8.2.2

Operating manual

5-seconds control signal

The 5-seconds control signal triggers one single dispensing process at pump body
2 if a pump body 2 is present. After a specific pause time, this control signal can be
repeated, or a different control signal can be transmitted.
The lubricator reacts to control signals at PIN 2 only in a specific operating status. The
operating statuses are transmitted by the lubricator via PIN 4 as high-/low-level signal
and must be picked up and processed accordingly in the PLC.
Description: The lubricator is properly connected bothto an external control system via the electricalinterface and to the voltage supply.

U
24V
PIN 2

0V

5s
2s

t
Tp
Tp >25s
>22s

o.E.

U
24V
PIN 4

0V

Tp:
MR:

>3s

<7 ML >17 s>3st

 The lubricator sends a permanent output
signal (high-level) to PIN 4 indicating
readiness to the external control system(PLC). This output signal must be active
permanently and without interruption for>3 seconds. Only if this condition is met,
activation by an external control system ispossible.
 The 5-seconds control signal with a highlevel signal duration of 5 (4.9 ... 5.1) seconds
can be sent to the lubricator from the external
control system (PLC).

o.E.

Pause time
Motor run

 Directly after release of the signal the motor run (MR) of the lubricator is started and0.15 cm³ of lubricant is conveyed to the outlet. At the same time as the start of motorrun (MR), a low-level output signal is sent for confirmation by the lubricator to theexternal control system (PLC) for the duration of the motor run (MR).
 The motor runtime (MR) depends on various conditions like the counter-pressureestablished or present in the hydraulic system and the temperature. The motor runtime(MR) of the lubricator is 7...17 seconds.
 After completion of a faultless and successful motor run (MR), the output signal to the
lubricator changes from a low-level to a high-level signal.
 Not before >3 seconds after the end of the faultless and successful motor run, thenext control signal can be sent by the external control system (PLC). In the meantime,
the lubricator does not process any control signals.

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Operating manual To ensure reliable and clear recognition of the control signal, a pause time must be
observed. For the 5-seconds control signal, a pause time (Tp) of at least 25 seconds
applies for the lubricator between two identical or different control signals.
 If an error is recognized by the integrated microelectronics of the lubricator during or
directly after the end of a motor run (MR), this fault is transmitted to the external control
system (PLC) by means of a respective output signal (chapter 8.3).
8.2.3

8-seconds control signal

The 8-seconds control signal triggers one single dispensing process at pump body 1
and pump body 2 if a pump body 2 is present. After a specific pause time, this control
signal can be repeated, or a different control signal can be transmitted.
The lubricator reacts to control signals at PIN 2 only in a specific operating status. The
operating statuses are transmitted by the lubricator via PIN 4 as high-/low-level signal
and must be picked up and processed accordingly in the PLC.
Description: The lubricator is properly connected both to an external control system via theelectrical interface and to the voltage supply.
 The lubricator sends a permanent output signal (high-level) to PIN 4 indicating
readiness to the external control system (PLC). This output signal must be active
permanently and without interruption for >3 seconds. Only if this condition is met,
activation by an external control system is possible.
 The 8-seconds control signal with a high-level signal duration of 8 (7.9 ... 8.1)
seconds can be sent to the lubricator from the external control system (PLC).
 Directly after release of the signal the motor run (MR) of the lubricator is started and0.15 cm³ of lubricant is conveyed to the outlet. At the same time as the start of motorrun (MR), a low-level output signal is sent for confirmation by the lubricator to theexternal control system (PLC) for the duration of the motor run (MR).
 The motor runtime (MR) depends on various conditions like the counter-pressureestablished or present in the hydraulic system and the temperature. The motor runtime(MR) of the lubricator is 7...17 seconds.
 After completion of a faultless and successful motor run (MR), the output signal to the
lubricator changes from a low-level to a high-level signal.

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Operating manual Not before >3 seconds after the end of the faultless and successful motor run, thenext control signal can be sent by the external control system (PLC). In the meantime,
the lubricator does not process any control signals.
 To ensure reliable and clear recognition of the control signal, a pause time must be
observed. For the 8-seconds control signal, a pause time (Tp) of at least 45 seconds
applies for the lubricator between two identical or different control signals.
 If an error is recognized by the integrated microelectronics of the lubricator during or
directly after the end of a motor run (MR), this fault is transmitted to the external control
system (PLC) by means of a respective output signal (chapter 8.3).
8.2.4

12-seconds control signal

The 12-seconds control signal triggers the FIL function by the external control system.
A total of 40 dispensing processes per pump body are automatically executed one after
the other. After a specific pause time, this control signal can be repeated, or a different
control signal can be transmitted.
The lubricator reacts to control signals at PIN 2 only in a specific operating status. The
operating statuses are transmitted by the lubricator via PIN 4 as high-/low-level signal
and must be picked up and processed accordingly in the PLC.
Description:
U
24V

 The lubricator is properly connected bothto an external control system via the electricalinterface and to the voltage supply.

PIN 2

0V

t

12s

o.E.

Tp >706s

U
24V
PIN 4

0V

>3s

P
ML

P
ML

P
ML

40xML + 40xP

Tp:
P:
MR:

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t

P
ML

o.E.

 The lubricator sends a permanent output
signal (high-level) to PIN 4 indicating
readiness to the external control system(PLC). This output signal must be active
permanently and without interruption for>3 seconds. Only if this condition is met,
activation by an external control system ispossible.
 The 12-seconds control signal witha high-level signal duration of 12 (11.9 ... 12.1)
seconds can be sent to the lubricator from theexternal control system (PLC).

Pause time
Pause
Motor run

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Operating manual Directly after release of the signal the first motor run (MR) of the lubricator is started
and 0.15 cm³ of lubricant is conveyed to the outlet. At the same time as the start of
motor run (MR), a low-level output signal is sent for confirmation by the lubricator to theexternal control system (PLC) for the duration of the motor run (MR).
 The motor runtime (MR) depends on various conditions like the counter-pressureestablished or present in the hydraulic system and the temperature. The motor runtime(MR) of the lubricator is 7...17 seconds.
 After completion of every faultless and successful motor run (MR), the output signal
to the lubricator changes from a low-level to a high-level signal for a short pause time of
P = 0.5 seconds.
 This is followed by a total of 40 successive motor runs and dispensing processes.
In this process, a lubricant volume of 40 x 0.15 cm³ = 6.0 cm³ is conveyed from the
cartridge to the outlet.
 Not before >3 seconds after the end of the last faultless and successful motor
run, the next control signal can be sent by the external control system (PLC). In themeantime, the lubricator does not process any control signals.
 To ensure reliable and clear recognition of the control signal, a pause time must
be observed. For the 12-seconds control signal, a pause time (Tp) of at least 706(Tp=MRmaxx40 strokes+Px40 strokes+tolerance) seconds applies for the lubricator
between two identical or different control signals.
 At a lubricator with two pump bodies, triggering of the 12-seconds control signal
leads to 40 filling strokes per pump body. The pause time (Tp) is doubled.
 If an error is recognized by the integrated microelectronics of the lubricator during
or directly after the end of a motor run, this fault is transmitted to the external control
system (PLC) by means of a respective output signal (chapter 8.3.4).

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8.2.5

Operating manual

14-seconds control signal

The 14-seconds control signal serves for acknowledgment of error messages. Thisis the only control signal that can be processed by the lubricator if a low-level output
signal is sent. Irrespective from the general possibility of remote error acknowledgment,
the cause of every error message must be identified and corrected.
Description:U The lubricator is properly connected bothto an external control system via the electricalinterface and to the voltage supply.
 An error occurred at the lubricator.

24V
PIN 2

0V

14s
10s

U

t
o.E.

24V
PIN 4

0V

>3s

 The lubricator sends a permanent output
signal (low-level) to PIN 4 indicating an error
to the external control system (PLC). This
output signal must be active permanently andwithout interruption for >3 seconds.
 The 14-seconds control signal with ahigh-level signal duration of 14 (13.9 ... 14.1)
seconds can be sent to the lubricator from theexternal control system (PLC).

to.E.

 After the control signal, the following automatic checks are carried out by the
integrated microelectronics of the lubricator:+ If this internal check is successful, the output signal at the lubricator changes froma low-level to a high-level signal, the fault is thus acknowledged, and the lubricator
is ready again.
- If this internal check is not successful, the lubricator continues sending a low-level
output signal. The error still applies. For further measures in this case, refer to:
Chapter 8.3.4.
 Not before >3 seconds after the high-level output signal is active again at PIN 4, thecontrol signal can be sent by the external control system (PLC). In the meantime, thelubricator does not process any control signals!
 Irrespective from the general possibility of remote error acknowledgment, the causeof every error message must be identified and corrected.

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8.3

Operating manual

Output signals – external control system (PLC)

Designation

Output signal (PIN 4)

DetailReady

High, permanent

Chapter 8Control signal received

High, permanent

Chapter 8

Low, 10...18 seconds

Chapter 8

Dispensing
Empty cartridge

0.5Hz square-wave signal, permanent Chapter 8.3.1

Fault

Low, permanent

If a permanent low-level output signal (0V) is active at PIN 4 for more than 3 seconds
and no dispensing is currently executed by the lubricator, an error occurred at the
lubricator. The signal only indicates that an error occurred at the lubricator. The causemust be identified and corrected by the operator. Chapters 8.3.2, 8.3.3 and 8.3.4
provide procedures and possible causes for the error messages at the pump.
8.3.1

Empty cartridge

The lubricator is equipped with a sensor recognizing when the lubricant cartridge
is empty. If the cartridge is empty, the conveying of lubricant by the lubricator isinterrupted. This way, it can be ensured that no air enters the lubricator or lubricant
lines. The empty message is sent to the external control system (PLC). For this,a dedicated and unique output signal can be easily, quickly and reliably recognized by
the external control system (PLC).
Description:U The lubricator is properly connectedboth to an external control system via
the electrical interface and to the voltage
supply.

24V
PIN 4

0V

1s

1s

1s

1s

1s

1s

1s

 The empty signal can only occur directly
t after dispensing.

 Acknowledgment of the empty signal is not necessary nor possible. Troubleshooting
measures are described in chapter 9.2.
 Until the empty cartridge is removed, the lubricator does not process any control
signals.

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The transfer of the output signals when changing a cartridge at the switched-on
lubricator is illustrated and described below:
U
24V
PIN 4

Description: The lubricator is properly connected bothto an external control system via the electricalinterface and to the voltage supply.

 The empty cartridge occurred after0V
t dispensing, the output signal of the lubricator
E1 0,5 Hz
E1 lowis the 0.5Hz square-wave signal (empty signal)
Z1
Z2(0/+24V).
Z1:
Removal of empty cartridge  Z1 indicates the time the empty cartridge is
Z2:
Connection of new cartridge removed. The output signal of the lubricator now
changes from a 0.5Hz square-wave signal toa permanent low signal (0V).
 Z2 indicates the time a new full cartridge is connected. The output signal of the
lubricator now changes from the permanent low signal (0V) to a permanent high signal(+24V). This way, the lubricator signals to the external control system (PLC) that it isready again.
 If the empty cartridge signal has occurred during execution of the 12-seconds control
signal, the remaining strokes are executed after attachment of the new cartridge.
 Until all errors are corrected, the lubricator does not process any control signals.

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8.3.2

Operating manual

Overload error

During dispensing, the overload error indicates a hydraulic overload, i.e. if the
maximum pressure is exceeded.

U
24V
PIN 4

0V

t

>3s

Description: The lubricator is properly connected both to an external control system via theelectrical interface and to the voltage supply.
 Directly before the "overload" error occurs, the lubricator was successfully activatedby the external control system (PLC) and has attempted to execute dispensing.
 When the maximum admissible pressure is reached during/after dispensing, thelubricator sends a permanent low-level output signal (0V) at PIN 4 to the external
control system (PLC).
 Check the connection lines between the lubricator and the supplied lubrication points
and correct any causes.
 The overload error must be acknowledged with the 14-seconds control signal(chapter 8.2.5) after correction of the cause(s).
 Until all errors are corrected, the lubricator does not process any control signals.

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8.3.3

Operating manual

Undervoltage/overvoltage error

The undervoltage/overvoltage error indicates that the voltage supply of the lubricator is
not within the required parameters.

U
24V
PIN 4

0V

t

>3s

Description: The lubricator is properly connected both to an external control system via theelectrical interface and to the voltage supply.
 If the supply voltage is too low, the lubricator sends a permanent low-level output
signal (0V) at PIN 4 to the external control system (PLC).
 Check the supply voltage and compare it with the parameters specified in thetechnical data of the lubricator.
 The undervoltage/overvoltage error must be acknowledged with the 14-seconds
control signal (chapter 8.2.5) after correction of the cause(s).
 Until all errors are corrected, the lubricator does not process any control signals.

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8.3.4

Operating manual

Fatal error

The error E4 (fatal error) indicates that the integrated microelectronics have recognizeda fatal error and that the lubricator is not working within the permissible parameters.
This may be caused by mechanical, electronic or other defects.

U
24V
PIN 4

0V

t

>3s

Description: The lubricator is properly connected both to an external control system via theelectrical interface and to the voltage supply.
 The (fatal) error E4 was recognized during (internal) diagnosis.
 The error E4 can have different causes:
1. Increased voltage for a short time, 28...30V, and too short motor runtime.
2. The connected supply voltage was too low and the motor runtime too long.
In these cases, the error is corrected by switching the lubricator off and on again.
Important! Between switching the lubricator off and on, 60 seconds must be waited.
If the error E4 still persists, disassemble the lubricator and return it with the lubricant
cartridge and a description of the error to WITTENSTEIN alpha GmbH.
 Do not open the lubricator without permission! Observe the applicable information
and regulations for intended use (chapter 2.5) and warranty (chapter 2.6) specified inthis manual!

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9.

Operating manual

Maintenance and disposal Before carrying out any maintenance or work, please note the general safety
instructions (see chapter 2) and observe all applicable local and operational safety
regulations.
 Do not bypass or deactivate any safeguards without authorization!

9.1

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

Commissioning

After 500
hours or3 months

Annually

If
necessary

Cleaning

x

x

x

x*

Visual inspection

x

x

x

x*

Cartridge change

x**

x***

x*

Maintenance

*
**
***
9.1.1

Depending on application conditions and lubricant consumption
Depending on the delivery condition (ordered version)
Recommended after 2 years at the latest
Visual inspection

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

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9.1.2

Operating manual

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 theseals of the lubricator and to contamination of the lubricator or
lubricant by dirt and particles.
§ Do not use any compressed air for cleaning of the lubricator.
9.1.3

Recommissioning Reinstall all safeguards and make sure that all tools have been removed from thehazard area.
 Make sure that the lubricator is activated.
 Carry out a "quick check" (test run) with the 2-seconds signal (chapter 8.2.1).

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9.2

Operating manual

Cartridge change

NOTICE
Already opened lubricant cartridges must not be reattached to
the lubricator, as the integrated stroke counter of the lubricator
is automatically reset by the cartridge sensor after a cartridge
is removed.
§ Always use full lubricant cartridges.

NOTICE
Only use original lubricant cartridges with lubricants approvedby the manufacturer.
§	Observe the maximum storage time of lubricants filled in
cartridges.



NOTICE
Refilling of empty or open lubricant cartridges is not possible.

NOTICE
Make sure that the same lubricant is used in the new cartridgeas already used before. Make sure that only cartridges with thesame capacity are used.
§ Compare the information on the lubricant cartridge.

The change of lubricant cartridges at the lubricator is very easy and only requires five
steps.
The cartridge only needs to be changed if it is empty or if the useful life of the lubricant
was exceeded. Cartridges can be changed during normal operation of the lubricator.
Besides changing the cartridge, no additional measures are necessary!
Empty cartridge at the lubricator.

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1. Removal the top part from the drive unitof the lubricator.
 Turn the union nut counter-clockwise toremove the top part from the drive unit.
 Ensure that the work is carried out
under clean conditions. Dirt and particles
must not enter the lubricant inlet. If
necessary, carry out any cleaning before(chapter 9.1.2).

2. Removal of empty cartridge.
 Turn the lubricant cartridge counterclockwise to remove it from the lubricatorand dispose of it.
 Ensure that the work is carried out
under clean conditions. Dirt, fluids andparticles must not enter the cartridge.

3. Unscrewing the cartridge cap.
 Turn the cap of the lubricant cartridge
counter-clockwise to open it and remove it.
 Ensure that the work is carried out
under clean conditions. Dirt, fluids andparticles must not enter the cartridge.

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4. Connection of the new lubricant
cartridge.
 Set the full lubricant cartridge on the
lubricator.
 Turn the lubricant cartridge clockwise totighten it at the lubricator.

 The final position is reached after 2 fullturns if the label of the lubricant cartridge
is aligned flush with the front of the
lubricator.

5. Assembly of the top part from the drive
unit of the lubricator.
 Set the removed top part on the
lubricator and push it on the drive unit.
 Turn the union nut clockwise to attach
the top part to the drive unit.
 When turning the union nut, it must
notably lock into place and be fullytightened.

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Operating manual All work must be carried out according to the provided description.
 If an error was indicated by the return signal before the cartridge change, the display
goes off. Separate acknowledgment is not required.
 If the empty cartridge occurred during a dispensing cycle (conveying), it isautomatically interrupted and continued after the work is completed.
9.3

Disposal
 For disposal of the lubricator as well as any empty or opened cartridges, applicablenational regulations must be observed.
 For disposal, the respective safety data sheets and disposal instructions for theindividual components must be observed.
 Refilling of empty lubricant cartridges is not possible.

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9.4

Operating manual

Lubricants
Only use lubricants approved by WITTENSTEIN alpha GmbH in dedicated original
cartridges exclusively developed for the lubricator.



NOTICEThe 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, pleasecontact WITTENSTEIN alpha GmbH directly.
9.5

Line lengths
In general, the lubricator should be installed as closely as possible to the device to besupplied (lubrication point). Ideally, this should be directly at the lubrication point. If thisis not possible due to space restrictions or reasons regarding accessibility, lines can beused between the lubricator and the lubrication point (e.g. distribution).
If the lubricator cannot be installed directly at the lubrication point, please contact the
manufacturer to verify your application.
Due to variations in temperature, the used grease, hoses and accessories, no generalstatement can be made about the possible length of any hoses at the lubricator.

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9.6

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Operating manual

EC/EU declaration of conformity2022-D047797

en-39

WITTENSTEIN alpha GmbH · Walter-Wittenstein-Straße 1 · 97999 Igersheim · Germany
Tel. +49 7931 493-0 · info@wittenstein.de

WITTENSTEIN – one with the futurewww.wittenstein.com