3842358814 2017 01 NEW LU2 - dc-us.resource.bosch.com€¦ · precautions” and Chapter 3 “General notes on property and product damage”, and before a course of action or a required

Assembly instructions3 842 358 814/2017-01

Replaces: 2016-10ENGLISH

LU 2Automatic lubrication unit

3 842 543 482

3 842 543 483

3 842 543 484

3 842 543 485

3 842 543 486

3 842 543 487

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Bosch Rexroth AG, MIT: LU 2, 3 842 358 814/2017-01

The data specifi ed only serve to describe the product. The information provided in the instructions on how to use the supplied product should only be considered application examples and suggestions. Catalog information is not binding. The information given does not release the user from the obligation of own judgment and verifi cation. Our products are subject to a natural process of wear and aging.

© This document, as well as the data, specifi cations and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent.

An example confi guration is shown on the title page. The delivered product may thus vary from the illustration.

The original assembly instructions were generated in German.

DE Die vorliegende Montageanleitung ist in den hier angebenen Sprachen verfügbar. Weitere Sprachen auf Anfrage. Als gedruckte Version (print) oder als PDF-Datei (media) zum Download aus dem Medienverzeichnis: www.boschrexroth.com/medienverzeichnis Geben Sie in die Suchmaske (oben rechts, unter „Suche“) 3 842 358 814 ein, dann klicken Sie auf „ Suche“.

EN These assembly instructions are available in the languages indicated here. Other languages on request. They come in a hard copy (print) or a PDF fi le (media) that can be downloaded at: www.boschrexroth.com/mediadirectory Enter 3 842 358 814 in the search mask (at the top right, under “Search”), then click “ Search”.

FR Les présentes instructions de montage sont disponibles dans les langues spécifi ées ici. Autres langues sur demande. En version imprimée (print) ou en version PDF (media) téléchargeable sur le répertoire multimédia : www.boschrexroth.com/mediadirectory Saisissez 3 842 358 814 (en haut à droite, sous « Search »), puis cliquez sur « Search ».

IT Le presenti istruzioni di montaggio sono disponibili nelle lingue seguenti. Altre lingue su richiesta. Scaricabile come versione stampata (print) o come fi le PDF (media) dal Media Directory: www.boschrexroth.com/mediadirectory Digitare il codice 3 842 358 814 nel campo di ricerca “Search” (in alto a destra), quindi fare clic su “ Search”.

ES Las presentes instrucciones de montaje están disponibles en los idiomas indicados. Hay más idiomas a petición. Las instrucciones están disponibles como versión impresa (print) o como archivo PDF (media) para descargar del archivo de medios: www.boschrexroth.com/mediadirectory En el buscador (en la parte superior derecha, donde pone "Search") introduzca 3 842 358 814, a continuación haga clic en " Search".

PT-BR

Este manual de montagem está disponível nos idiomas especifi cados aqui. Outros idiomas mediante pedido. Como versão impressa (impressão) ou como arquivo PDF (mídia) para download do índice de mídias: www.boschrexroth.com/mediadirectory Entre na máscara de pesquisa (canto superior direito, em «Search») 3 842 358 814 e clique em « Search».

ZH 本安装说明书有这里给出的语言版本。有印刷版本 (print) 或者电子版 PDF 文件 (media) 供使用，电子版文件可在下列的公司网站媒体网页上下载: www.boschrexroth.com/mediadirectory 1. 在搜索窗口 (右上角，“Search”窗口) 内输入编号 3 842 546 292。2. 点击“ Search”。

CS Tento návod k montáži je k dispozici ve zde uvedených jazycích. Jako tištěná verze (print) nebo jako soubor PDF (media) je ke stažení z adresáře médií: www.boschrexroth.com/mediadirectory 1. Zadejte do vyhledávací obrazovky (nahoře vpravo, pod „Search“) MTCS 358 814. 2. Klikněte na „ Search“.

PL Dana instrukcja montażu jest dostpna w podanych tutaj językach. W postaci wydrukowanej lub w wersji pdf (media) do pobrania ze strony: www.boschrexroth.com/mediadirectory 1. Do wyszukiwarki wpisać (w prawym górnym rogu „Search“) MTPL 358 814 . 2. KKliknać „ Search“

HU A jelen szerelési utasítás az itt megadott nyelveken áll rendelkezésre. További nyelvek rendelésre. A nyomtatott (print) változat vagy a PDF-fájl (media) letölthető a médiakönyvtárból: www.boschrexroth.com/mediadirectory

Írja be a keresőmezőbe (fent jobbra a „Search“ alatt) MTHU 358 814, majd kattintson a „ Search“ gombra.

3 842 358 814 print media LU 2 Automatische Schmiereinheit DE Deutsch3 842 358 814 print media LU 2 Automatic lubrication unit EN English3 842 358 814 print media LU 2 Unité de lubrifi cation automatique FR Français3 842 358 814 print media LU 2 Unità di lubrifi cazione automatica IT Italiano3 842 358 814 print media LU 2 Unidad de lubricación automática ES Español3 842 358 814 print media LU 2 Unidade de lubrifi cação automática PT Português3 842 546 292 print media LU 2 自动润滑单元 ZH 中文MTCS 358 814 media LU 2 Automatická mazací jednotka CS ČeskyMTPL 358 814 media LU 2 Zespół automatycznego smarowania PL PolskiMTHU 358 814 media LU 2 Automatikus kenőegység HU Magyar

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3 842 358 814/2017-01, MIT: LU 2, Bosch Rexroth AG

3/54 Contents

1 About this document 51.1 Scope of document 51.2 Required and supplementary documentation 51.3 Presentation of information 51.3.1 Safety instructions 51.3.2 Symbols 61.3.3 Designations 72 Safety instructions 72.1 About this chapter 72.2 Intended use 72.3 Improper use 82.4 Qualifi cation 82.5 General safety information 82.6 Product-specifi c safety instructions 92.7 Personal protective equipment 102.8 Owner obligations 103 General information regarding damage to property and the product 104 Scope of delivery 114.1 Delivery state 114.2 Accessories 115 About this product 115.1 Performance description 115.1.1 Automatic lubrication unit LU 2 use 115.1.2 Automatic lubrication unit LU 2 design 115.2 Product description 125.3 Identifi cation of the product 136 Function 146.1 TIME mode 146.1.1 Setting the delivery volume in the TIME operating mode 156.1.2 Display of the remaining delivery period 166.2 PULSE mode 176.2.1 Setting the delivery volume in the PULSE operating mode 186.3 Required delivery volume 206.3.1 Flat top chain: every 1000 h 206.3.2 Flat top chain: every 2000 h 206.3.3 Accumulation roller chain: every 1000 h 216.3.4 Accumulation roller chain: every 2000 h 216.3.5 Vplus accumulation roller chain: every 1000 h 226.3.6 Vplus accumulation roller chain: every 2000 h 226.4 Special delivery PURGE 236.5 PIN number 246.6 Counter pressure monitoring 246.7 Low temperature monitoring 246.8 Indicator elements and signal outputs 256.8.1 LED indicators and display 256.8.2 Signal outputs 25

Contents

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6.8.3 Cable break detection 257 Transport and storage 267.1 Transporting the product 267.2 Storing the product 268 Installation 278.1 Unpacking 278.2 Installation requirements 278.2.1 Installation position 278.2.2 Mounting with T-bolts 278.3 Required tools 278.4 Symbols used 288.5 Installing the product 298.5.1 Install the holder for the lubrication unit LU 2 298.5.2 Install support bracket and connector set in the holder 308.5.3 Install lubrication unit LU 2 318.5.4 Install adapter Set AS 2/C-100, -250 338.5.5 Install adapter Set AS 2/C-400, AS 2/C-700 348.5.6 Install adapter Set AS 2/R-300, AS 2/R-700 358.5.7 Install adapter Set AS 2/R-1200, AS 2/R-2200 368.5.8 Install adapter Set AS 2/R-1200, AS 2/R-2200 378.6 Make the electrical connection to the product 388.6.1 PLC programming suggestions for evaluating the signal outputs 399 Start-up 419.1 First-time operation 419.1.1 Short description commissioning 429.2 Re-commissioning after a standstill period 4210 Operation 4310.1 Notices regarding operation 4310.1.1 Wear 4310.1.2 Steps for reducing wear 4310.1.3 Environmental infl uences 4311 Maintenance and repair 4411.1 Cleaning and care 4511.2 Inspection 4511.3 Maintenance 4511.4 Replacement of worn parts 4511.4.1 Exchange oil container LC 2 4611.4.2 Exchange battery LU 2 4811.4.3 Replacement parts 4812 Shutdown 4913 Disassembly and replacement 4913.1 Preparing the product for storage/further use 4914 Disposal 5015 Upgrading and modifi cation 5016 Troubleshooting 5117 Technical data 5217.1 Storage period 5217.2 Ambient conditions 53

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1 About this document

1.1 Scope of documentThis documentation applies to the following products: • Lubrication unit LU 2, 3 842 543 482 • Adapter Set AS 2/C-100, -250, 3 842 543 483 • Adapter Set AS 2/C-400, -700, 3 842 543 484 • Adapter Set AS 2/R-300, -700, 3 842 543 485 • Adapter Set AS 2/R-1200, -2200, 3 842 543 486 • Adapter Set AS 2/R-V, 3 842 543 487 • Oil container LC 2, 3 842 543 469

This manual is intended for engineers, operators, service engineers and system end users.This document contains important information to install, transport, commission, operate, use, maintain, and dismantle the product safely and correctly and on simple troubleshooting.

Read this manual completely, especially chapter 2 “Safety” and Chapter 3, “General notes for property damage and product damage” before working with the product.

1.2 Required and supplementary documentation Only operate when you are in possession of the documentation marked with the

book symbol and you have understood and observed this.

Table 1: Required and supplementary documentation

Title Document number Document type

Safety-related information for staff 3 842 527 147

MTparts 3 842 529 770 Spare part list available on CD

1.3 Presentation of informationIn order for you to work with your product quickly and safely using this documentation, safety symbols, terms and abbreviations are used in a uniform manner. These are explained in the following sections to help you understand them better.

1.3.1 Safety instructionsIn this documentation, safety instructions are given in chapter 2.6 “Specifi c product precautions” and Chapter 3 “General notes on property and product damage”, and before a course of action or a required action, in which there is a risk of personal injury or property damage. Be sure to observe all safety precautions.

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Safety instructions are set out as follows:

SIGNAL WORDType and source of danger!Consequences of non-compliance

Measures to prevent hazards …

• Warning sign: points out the hazard • Signal word: identifi es the severity of the hazard • Type and source of danger: indicates the type and source of the danger • Consequences: describes what occurs when failing to take precautions • Precaution: states how the hazard can be avoided

Table 2: Hazard classes according to ANSI Z535.6-2006

Warning sign, signal word Meaning

DANGERIndicates a hazardous situation which will result in death or serious injury if not avoided.

WARNINGIndicates a hazardous situation which can result in death or serious injury if not avoided.

CAUTIONIndicates a hazardous situation which can result in minor or moderate injury if not avoided.

NOTICE Damage to property: The product or the environment could be damaged.

1.3.2 SymbolsThe following symbols indicate notices which are not safety-relevant but make the layout of the document more clear.

Table 3: Meaning of the symbols

Symbol Meaning

If this information is not observed, the product cannot be used and/or operated optimally.

Single, non-related actions

1. 2. 3.

Numbered instructions:The numbers indicate that the actions must be carried out one after the other.

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1.3.3 DesignationsIn this documentation, the following designations are used:

Table 4: Designations

Designation Meaning

LU 2 Automatic lubrication unit from the Rexroth transfer system TS 2plus

LC 2 Oil container for the automatic lubrication unit LU 2

AS 2/… Adapter set for the automatic lubrication unit LU 2

2 Safety instructions

2.1 About this chapterThis product has been manufactured using state-of-the-art technology. Nevertheless, there is a risk of personal injury and property damage if you do not observe this chapter and the safety instructions in this document.

Read this manual thoroughly and completely before you start working with the product.

Keep these instructions accessible to all users at all times. Always include the operating instructions when transferring this product

to third parties.

2.2 Intended useThe product is an incomplete machine.This product may be used for the following: • for installation in a Rexroth transfer system TS 2plus for lubrication of the transport chain.

• for lubrication of 1 belt section BS 2/… or 1 section unit SE 2/…in the drive station. • for operation with 2 equal lubrication pins. • For the environmental conditions see page 53.

The product is strictly intended for professional use and not for private use.The intended use also implies that you have read and understood this documentation, especially chapter 2 “Safety”.

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2.3 Improper useAny use other than that described in Chapter “Intended use” is considered improper and is not permitted.Bosch Rexroth AG is not liable for any damages resulting from improper use. The user is solely responsible for the consequences of improper use.The following also fall under the category of improper use: • Using the product for lubrication of more than 1 belt section BS 2/… or 1 section unit SE 2/… .

• Using the product with other than the specifi ed lubricant. • Using the product with non-specifi ed accessories. • Using the product with lubrication lines unequal length. • Using the product with unequal lubrication pins. • Using the product without ensuring that it is in the correct position. • Private use.

2.4 Qualifi cationThe activities described in this documentation require basic knowledge of mechanical, electrical and pneumatic systems, as well as knowledge of the appropriate technical terms. Additional knowledge in dealing with a hoist and the associated slings are required for transport and handling of the product. To ensure safe use, these activities may only be performed by a specialist or personnel under the direction of a specialist.“Specialist” refers to a person who can recognize potential hazards and take appropriate safety measures due to their technical training, knowledge and experience, and understanding of the relevant regulations pertaining to the work being performed. Qualifi ed personnel must comply with the relevant technical regulations and have the necessary expertise.

Bosch Rexroth offers training to support activities in specifi c areas. You can fi nd an overview of the training content online at http://www.boschrexroth.de/didactic

2.5 General safety information • Observe the regulations for accident prevention and environmental protection. • Observe the safety rules and regulations of the country in which the product is used/applied.

• Only use Rexroth products that are in good working order. • Follow all instructions printed on the product. • Persons who assemble, operate, disassemble, or maintain Rexroth products must not consume any alcohol, drugs, or pharmaceuticals that may affect their reaction time.

• Use only original accessories and spare parts from Rexroth to prevent hazards to persons due to improper spare parts.

• Observe the technical data and ambient conditions listed in the product documentation.

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• You may operate the product only when it was found that the fi nal product (such as a machine or system), in which the Rexroth products are installed, is in accordance with the respective national provisions, safety regulations and the standards for the application.

2.6 Product-specifi c safety instructions • Do not modify or alter the product. • Do not expose the product to unacceptable mechanical loads under any circumstances. Never use the product as a handle or step. Do not place objects on it.

• Always secure the product against tipping. • Observe the transport information on the packaging. • Check the product for visible damage during transport. • Lay the cables and lines so that they cannot be damaged and no one can trip over them.

• Make sure the relevant system component is not under pressure or voltage before assembling the product or when connecting and disconnecting plugs.

• Secure the system component from being switched on. • Before start-up, make sure that all seals and caps for the screwed connections are correctly installed and undamaged to prevent fl uids and debris from infi ltrating the product.

• Allow the product to acclimate for a few hours before start-up, otherwise condensation may form in the housing.

• Make sure that all electrical connections are either used or covered. • Check the security requirements according to DIN EN 619. • Start up the product only if it is installed completely. • Make sure that all safety equipment belonging to the product is present, has been installed properly, and is fully functional. Do not displace, bypass, or disable the safety equipment.

• Do not reach into moving parts. • Check the product for malfunctions. • Make sure only authorized personnel perform the following within the scope of intended use: – Start or operate the system, or intervene in its normal functioning. – Operate adjustment devices on components.

• Only allow persons who are authorized by the owner to access the product's direct operating area. This also applies when the product is standing still.

• Make sure that: – There are no obstacles preventing access to the EMERGENCY STOP control units. – All delivery points, workstations and passages remain freely accessible.

• Do not use EMERGENCY STOP control units for routine stops. • Regularly check the proper functioning of the EMERGENCY STOP control units. • In the event of an error or other irregularities, after an EMERGENCY STOP turn the product off and secure it against restarting.

• Do not reach into moving parts. • An idle system is not a safe system, as stored energy can be released unintentionally or through improper maintenance procedures.

General

During transportDuring assembly

During start-up

During operation

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• After an EMERGENCY STOP or a malfunction, only switch on the system once the cause of the fault has been determined and the error resolved.

• Make sure that there are no obstacles blocking access to maintenance and inspection points.

• Perform the prescribed maintenance work at the intervals prescribed in chapter 10.3 Maintenance.

• Make sure that no lines, connectors, or components are disconnected as long as the system is under pressure and voltage. Secure the system against being switched back on.

• Dispose of the product in accordance with the currently applicable national regulations in your country.

2.7 Personal protective equipment • Appropriate protective clothing is to be worn when handling the product (e.g. safety shoes, close-fi tting clothing, a hair net for long, loose hair). As owner or operator, you are responsible for appropriate protective equipment when using the product. All personal protective equipment must be intact.

2.8 Owner obligations • Before fi rst use or re-commissioning of a conveyor system, run a risk assessment in accordance with DIN EN ISO 12100.

• Before initial commissioning ensure that there are no protruding or sharp-edged parts that may endanger personnel working or moving in the area.

• Provide safety-related instructions to the operating personnel before fi rst use or re-commissioning, and then in regular intervals.

3 General information regarding damage to property and the product

The warranty only applies to the delivered confi guration. • The warranty is void in case of faulty installation, commissioning and operation, as well as improper use and / or improper handling.

• Avoid the penetration of detergent into the system. • Never use solvents or aggressive detergents. • Do not use a high-pressure cleaner for cleaning.

EMERGENCY STOP, fault

During maintenance and repair

During disposal

During cleaning

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4 Scope of delivery

The following is included in delivery: • 1 Automatic lubrication unit LU 2 • Assembly instructions for “Automatic lubrication unit LU 2”

4.1 Delivery stateUnassembled in parts.

4.2 Accessories(not included in the delivery) • Oil container LC 2, 3 842 543 469 • Adapter Set AS 2/C-100, -250, 3 842 543 483 • Adapter Set AS 2/C-400, -700, 3 842 543 484 • Adapter Set AS 2/R-300, -700, 3 842 543 485 • Adapter Set AS 2/R-1200, -2200, 3 842 543 486 • Adapter Set AS 2/R-V, 3 842 543 487

5 About this product

5.1 Performance description

5.1.1 Automatic lubrication unit LU 2 use • Lubrication of concealed running transport chains in the transfer system TS 2plus. • for lubrication of 1 belt section BS 2/… or 1 section unit SE 2/…in the drive station. • Exclusively for operation with 2 equal lubrication pins.

5.1.2 Automatic lubrication unit LU 2 design • The automatic lubrication unit LU 2 consists of the components

– Lubrication unit LU 2, 3 842 543 482 – Oil container LC 2, 3 842 543 469 – Adapter Set AS 2/C-100, -250, 3 842 543 483 1)

– Adapter Set AS 2/C-400, -700, 3 842 543 484 1)

– Adapter Set AS 2/R-300, -700, 3 842 543 485 1)

– Adapter Set AS 2/R-1200, -2200, 3 842 543 486 1)

– Adapter Set AS 2/R-V, 3 842 543 487 1)

1) Not part of the delivery, please order separately.

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5.2 Product description

Fig. 1:

A

G

H

I

J

K

2x

2x

2x

2x

2x

C

E

F

B

358 814-01

D

Product description

A: Lubrication unit LU 2

B: Drive

C: Oil container LC 2 1)

D: Holder, complete with assembly accessories

E: Support bracket

F: Connection set

G: Adapter Set AS 2/C-100, -250 1)

H: Adapter Set AS 2/C-400, -700 1)

I: Adapter Set AS 2/R-300, -700 1)

J: Adapter Set AS 2/R-1200, -2200 1)

K: Adapter Set AS 2/R-V 1)

1) Not part of the delivery, please order separately.

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5.3 Identifi cation of the product

Fig. 2: Name plate

B

Typschild

. . . . . . . . . . . . . . . . .. . . . . . . . .

. . . . . . . . . . . . . .. . .. . . . . . . .

A

C

A: Part no.(Order number)

B: Designation

C: Design and dimensions

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6 Function

The lubrication unit LU 2 has two operating modes: • TIME mode • PULSE mode

A special delivery volume (PURGE) can also be triggered and the operation of the lubrication unit can also be disabled using a 2-digit PIN number.

The device is equipped with counter pressure and lower temperature monitoring.

Device settings are retained even after a power failure by the use of an integrated backup battery.

6.1 TIME modeA metering period (per month, 1 to 12 months) can be entered in the TIME mode.During this metering period metered volumes of lubricant are delivered at fi xed, regular intervals (interval period t [h:mm]). The volume of metered lubricant delivered is determined by the metering period, the interval period and the entered oil container LC 2.

Only in TIME mode: At the initial startup the drive runs for approximately 8 sec after the supply voltage is connected to prime the lubrication unit. The operation then starts with the fi rst interval time. When the interval time has expired the metered volume is delivered.

• The operating mode, the entered delivery period, the entered oil container LC 2 ( LC250) and the metered volume to be delivered per 100 hours are shown on the display.

• Metered lubricant deliveries are only executed when the supply voltage is connected. • Metered lubricant deliveries not executed because of a fault are automatically rescheduled at half the interval time.

Table 5: The delivery volume is determined by the delivery duration and interval

Delivery periodMonth

Interval timet [h:mm]

Delivery volume [cm³/100 h] with oil container LC 2 (= LC250)

1 1:30 34

2 3:00 17

3 4.36 11

4 6:06 8.5

5 7:36 6.8

6 9:06 5.7

7 10:36 4.8

8 12:12 4.2

9 13:42 3.8

10 15:12 3.4

11 16:42 3.1

12 18:12 2.8

358 814-25

Please note:(1 cm³ 0.9 g lubricant)

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6.1.1 Setting the delivery volume in the TIME operating modeThe mode of operation, the oil container used LC 2 ( LC250) and the delivery period is entered via the display using the SET button.The delivery period must be entered in relation to the required delivery volume, interval period and the oil tank used LC 2 ( LC250) (see Table 5 on page 14).

• The input is executed with the power supply disconnected. The power supply for the electronics comes from an integrated backup battery.

• The oil container LC 2 must be installed on the drive prior to the setting (see page 31).

In the as delivered condition the display is on the left.

1. Press and hold the SET button (> 5 s), until the modes TIME and PULSE fl ash in the display.

2. Press 1x the SET button.

The display switches to the TIME mode (TIME fl ashes).

After about 3 seconds, the display switches to the selection of the oil container.

3. Press SET button 1x LC60Press SET button 2x LC120Press SET button 3x LC250 (= LC 2)

The selected oil container fl ashes in the display (here LC250).

After about 3 seconds, the display switches to the entry of the metered lubricant delivery period.

4. To enter the delivery period press the SET button repeatedly. Months 1...12 can be scrolled through.

The delivery period entered fl ashes in the display.

Approximately 3 seconds after the entry (inactive SET button) the setting mode for the delivery period is terminated.

The operating mode, the entered delivery period, the entered oil container LC 2 ( LC250) and the metered volume to be delivered per 100 hours are shown on the display.

358 814-27

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358 814-30

358 814-31

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5. Turn on the power to the lubrication unit.Make the electrical connection to the product see page 38.

The plug icon (cable break detection, see page 25) appears in the display and the arrow icon flashes in the display. The drive LEDs flash green at 5 s intervals.

The initial start of the operation begins about 8 s after the supply voltage with the interval time.

6.1.2 Display of the remaining delivery periodDuring operation, the remaining delivery period can be shown in the display.

Press and hold the SET button during operation for > 1 s (fl ashing arrow icon in the display).

The display shows the remaining delivery time in hours.>999h hours appears in the display where the remaining delivery time is equal or greater than 1000 hours.

358 814-34

358 814-37

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6.2 PULSE modeIn PULSE mode delivery volume can be entered in defi ned steps.According to the volume of the oil container entered LC 2 (= LC250), a certain number of lubricant deliveries follow, with the appropriate delivery volume.

• The operating mode, the oil container used LC 2 (LC250), and the required delivery volume per pulse (delivery) are entered via the display using the SET button.

• If the number of remaining pulses (deliveries) is 100 or greater, the following indicator appears in the display >99 (Field in the table with a gray background).

• The delivery is carried out once with supply voltage (rising fl ank). • The supply voltage must be present at least as long enough for the delivery process to be completed (min. 2 minutes).

• Before the following delivery the supply voltage must be shut down for > 1 s. • The signaling/display of system states and errors is only possible when the supply voltage is present.

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Table 6: Number of deliveries is dependent on the volume of the metered lubricant to be delivered and the oil container LC 2

Delivery volume[cm³/pulse]

Number of pulses (delivery) per oil container LC 2 ( LC250)

0.1 2500

0.2 1250

0.3 833

0.4 625

0.5 500

0.6 417

0.7 357

0.8 313

0.9 278

1.0 250

1.2 208

1.4 179

1.6 156

1.8 139

2.0 125

2.2 114

2.4 104

2.6 96

2.8 89

3.0 83

3.5 71

4.0 62

4.5 56

5.0 50

5.5 45

6.0 42

6.5 38

7.0 36

7.5 33

8.0 31

8.5 29

9.0 28

9.5 26

6.2.1 Setting the delivery volume in the PULSE operating modeThe operating mode, the oil container used LC 2 ( LC250) and the required delivery volume per pulse (delivery) are entered via the display using the SET button.The number of pulses (deliveries) can be taken from Table 6 on page 18.

Please note:(1 cm³ 0.9 g lubricant)

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• The input is executed with the supply voltage disconnected. The power supply for the electronics comes from an integrated backup battery.

• The oil container LC 250 must be installed on the drive prior to the setting (see page 31).

In the as delivered condition the display is on the left.

1. press and hold the SET button (> 5 s), until the modes TIME and PULSE fl ash in the display.

2. Press 2x the SET button.

The display switches to the PULSE mode (PULSE fl ashes).

After about 3 seconds, the display switches to the selection of the oil container.

3. Press SET button 1x LC60Press SET button 2x LC120Press SET button 3x LC250 (= LC 2)

The selected oil container fl ashes in the display (here LC250).

After about 3 seconds, the display switches to the entry of the metered lubricant delivery volume.

4. To enter the delivery volume per pulse press the SET repeatedly. The delivery volume of 0.1...9.5 cm³/pulse can be scrolled through in the pre-entered steps.

The delivery volume entered per pulse fl ashes in the display.

Approximately 3 seconds after the entry (inactive SET button) the setting mode for the delivery volume is terminated.

The operating mode, the quantity of remaining pulses, the entered oil container LC 2 ( LC250) and the metered volume to be delivered per pulse are shown on the display.If the number of remaining pulses is 100 or greater, the following indicator appears in the display >99.

5. Turn on the power to the lubrication unit.Make the electrical connection to the product see page 38.

The plug icon (cable break detection, see page 25) appears in the display and the arrow icon flashes in the display. The drive LEDs flash green at 5 s intervals.

358 814-27

358 814-28

358 814-39

358 814-40

358 814-41

358 814-42

358 814-43

358 814-44

358 814-44

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6.3 Required delivery volume

6.3.1 Flat top chain: Required delivery volume for 2 - 3 g oil/m chain every 1000 h

Fig. 3:

1)

2)

2019181716151413121110987654321

11

6

1

y [h]

x [m]

358 814-16

Flat top chain: Required delivery volume for 2 - 3 g oil/m chain every 1000 h

6.3.2 Flat top chain: Required delivery volume for 2 - 3 g oil/m chain every 2000 h

Fig. 4:

1)

2)

2019181716151413121110987654321

11

6

1

y [h]

x [m]

358 814-16

Flat top chain: Required delivery volume for 2 - 3 g oil/m chain every 2000 h

x [m]: Section length

y [h]: Distance between the discharging operations

1): Delivery volume each pulse: 0.26 cm3






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6.3.3 Accumulation roller chain: Required delivery volume for 2 - 3 g oil/m chain every 1000 h

Fig. 5:

1)

2019181716151413121110987654321

25

10

5

15

20

0

y [h]

x [m]

358 814-17

Accumulation roller chain: Required delivery volume for 2 - 3 g oil/m chain every 1000 h

6.3.4 Accumulation roller chain: Required delivery volume for 2 - 3 g oil/m chain every 2000 h

Fig. 6:

1)

2019181716151413121110987654321

25

10

5

15

20

0

y [h]

x [m]

358 814-17

Accumulation roller chain: Required delivery volume for 2 - 3 g oil/m chain every 2000 h







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6.3.5 Vplus accumulation roller chain: Required delivery volume for 2 - 3 g oil/m chain every 1000 h

Fig. 7:

2) 3)

1)

2019181716151413121110987654321

7

6

5

2

3

4

1

y [h]

x [m]

358 814-18

Vplus accumulation roller chain: Required delivery volume for 2 - 3 g oil/m chain every 1000 h

6.3.6 Vplus accumulation roller chain: Required delivery volume for 2 - 3 g oil/m chain every 2000 h

Fig. 8:

2) 3)

1)

2019181716151413121110987654321

7

6

5

2

3

4

1

y [h]

x [m]

358 814-18

Vplus accumulation roller chain: Required delivery volume for 2 - 3 g oil/m chain every 2000 h











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6.4 Special delivery PURGEDuring operation a special delivery (PURGE) can be triggered at any time.

Press and hold the SET button during operation for > 10 s (fl ashing arrow icon in the display).

The message PU appears in the display and the special delivery is executed.The lubrication unit then returns to the preset operating mode.

The PURGE special delivery can be canceled at any time by pressing the SET button a second time.

358 814-38

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6.5 PIN numberThe operation of the lubrication unit can be disabled via a 2-digit PIN number.

1. Press and hold the SET button for > 15 s.

The display switches to the entry of the PIN number.

2. To enter the PIN number press the SET button repeatedly. The PIN number can be scrolled through from 1... 99.

The PIN number entered fl ashes in the display.

Approximately 3 seconds after the entry (inactive SET button) the setting mode for the PIN number is terminated.

When entering the PIN number 00 the operation of the lubrication unit is not locked.When entering 01... 99 the operation of the lubrication unit is locked and the PIN number will be requested to unlock.

6.6 Counter pressure monitoringThe lubrication unit LU 2 monitors the counter pressure of the lubrication point.If the lubrication unit LU 2 detects counter pressure > 6 4x in a row, a resting phase will follow (Recovery).In this resting period, the lubrication unit will try to deliver 3x, each with an interval of 16 hours.

If the counter pressure reduces during these three deliveries (48 h), the missed deliveries are automatically rescheduled at half the interval time.

If the counter pressure is not reduced during these three deliveries (48 h), an error message appears. The LED indicators fl ash red and 0L appears on the display.

6.7 Low temperature monitoringThe lubrication unit LU 2 monitors any low temperature of the lubrication point.If a temperature < -20 °C is detected and error message appears. The LED indicators fl ash red and ut appears on the display.

If the drive returns to a permissible temperature range, the display ut disappears and the drive is put back into operation by pressing and holding the SET button for > 1 s.

358 814-45

358 814-45

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6.8 Indicator elements and signal outputs

6.8.1 LED indicators and displayThe lubrication unit LU 2 has three LED indicators. The indicators are placed around the drive and visible from all sides. System status and errors are displayed via these LED indicators. All three LED indicators have an identical function.The system states and errors are also shown in the display.

Table 7: System states and indicators

System state LED indicator Indicator in display

System in operation Flashing green in 5 s intervals - Operating mode TIME or PULSE with appropriate parameters- Flashing arrow

Delivery process Flashing green in 1 s intervals ruError/fault drive Flashing red ErOil container LC 2 empty Flashing red LCSpecial delivery (PURGE) Flashing green in 1 s intervals PUCounter pressure too high (p > 6 bar)

Flashing red 0L

Low temperature (t < -20 °C) Flashing red utBackup battery drive empty - Lo

6.8.2 Signal outputsIn addition, the lubrication unit LU 2 has signal outputs OK and Err. These outputs can be evaluated by a connected controller to monitor the lubrication unit. System state conditions and faults can be detected.

Table 8: Signal states for the outputs OK and Err

Signal output Meaning

OK (Pin 2) Err (Pin 4)

1 0 OK (system in operation)

0 1 Err (error occurred)

0 0 Err (error occurred), Detection of cable break, see page 251 1 LC (oil container empty)

6.8.3 Cable break detectionThe lubrication unit monitors the signal outputs OK and Err for cable breaks. If a cable break is detected by the signal outputs, the plug symbol disappears from the display.

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7 Transport and storage

• Observe the transport information on the packaging. • Shipping weight: see delivery documents. • Secure the product to prevent toppling! • The ambient conditions must be controlled when storing and transporting; see page 53.

7.1 Transporting the product

WARNINGLifted loads may fall.Falling objects can result in serious injury (or even death).

Always use lifting equipment with suffi cient load bearing capacity (see shipping documents for product weight).

Make sure the carrying straps are correctly fastened before raising the product. Secure the product to prevent toppling while lifting. Make sure no one except the operator is in the danger area when raising and

lowering the product.

7.2 Storing the product • Only store the product on a fl at surface. • Protect the product from mechanical stress. • Protect the product from environmental infl uences such as dirt and moisture. • Pay attention to the ambient conditions, see page 53. • For belt sections with mounted motor-transmission combination and/or mounted lubrication unit: Support the belt section so that the motor-transmission combination or lubrication unit are not overloaded.

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8 Installation

8.1 Unpacking Lift the product from its packaging. Dispose of the packaging material in accordance with the national laws of

your country.

8.2 Installation requirements During installation the ambient conditions specifi ed in the technical data

(see page 53) must be maintained.

8.2.1 Installation position Install the product level and plumb at right angles and parallel to the axis.

This ensures proper functioning and prevents premature wear.

8.2.2 Mounting with T-bolts • Mount the transfer systems TS 1, TS 2plus, TS 2pv, TS 4plus, TS 5 and the chain conveyor systems VarioFlow and VarioFlow S with T-head bolt and collar nut.

• Make sure the T-bolt is in the correct position when inserting and tightening in the slot. The notch at the end of the bolt indicates the orientation of the T-bolt. 1 = T-bolt insertion position in the slot. 2 = T-bolt clamping position in the slot.

Tightening torque: 25 Nm (M8).

8.3 Required tools • Hex head cap screw SW13. • Hex socket head cap screw SW3, SW4, SW5, SW6. • Cross recess screwdriver PZ2 • Rubber mallet • Spirit level • Expanding pliers • Cutter to shorten the lubrication line.

21

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8.4 Symbols usedTable 9: Symbols used

21Connection with T-head bolt and collar nut.Make sure the T-bolt is in the correct position when inserting and tightening in the slot. The notch at the end of the bolt indicates the orientation of the T-bolt.1 = insertion position of the T-head bolt into the nut2 = clamping position of the T-head bolt into the nutTightening torque: 25 Nm

SW13MD = 20Nm

Hex keySW = screw width ... mmMD = necessary tightening torque … Nm

SW5 MD = 8Nm

Hex socket head cap screw keySW = screw width ... mmMD = necessary tightening torque … Nm

PH3PZ2

Screwdrivers for cross-head screwsPZ … = Pozidriv screwdriver, size …PZ … = Phillips screwdriver, size …

gleitmo585 K

Anti Seize

Lubricate / Lubricate with specifi c grease: • gleitmo 585 K: gleitmo 585 K, www.fuchs-lubritech.com • Anti-Seize: Food Grade Anti-Seize/Loctite 8014, www.henkel.com

weiconlockAN302-43

Please the following as thread locking and sealing means: • Weiconlock AN302-43: medium strength (detachable), www.weicon.de

The marked parts are not required for the assembly described. Dispose of the parts or use them for other purposes.

21 3Graphical depiction of assembly sequence. The numbers correspond to the sequence of assembly, in accordance with the instructions of the accompanying text.

A B C XGraphical depiction of components. The letters denote the components mentioned in the accompanying text.

Detail view from a different direction, for example, on the back or bottom of the product.

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8.5 Installing the product

8.5.1 Install the holder for the lubrication unit LU 2

Fig. 9:

MD= 10NmSW4

MD= 10NmSW4

MD= 10NmSW4

SW10

358 814-02

MD= 10Nm

B

A

SW4

max.±45°

max.±45°

Install the holder for the lubrication unit LU 2

Mount the holder vertically near the drive, either- at a transverse connector (A) or - below the section profi le (B).

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8.5.2 Install support bracket and connector set in the holder

Fig. 10:

E

F

358 814-20

Install support bracket and connector set in the holder

1. Pre-assemble the the support bracket (E) and the connection set (F).

2. Set the support bracket and the connection in the holder.

3. Connect hoses to the lubrication unit according to your application (see also page 33 to 37)

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8.5.3 Install lubrication unit LU 2

Fig. 11: 358 814-21

1

2

B

C

Y

OK

X

OK

Install drive on oil container LC 2

Please note:The oil container may only be bolted 1x.

1. Place the drive (B) on the oil container (C).

Please note:The rim of the drive must be placed seamlessly on the top of the oil container (X).

2. Screw the drive union nut on the oil container by hand.

Please note:The union nut must be able to be screwed onto the oil container so far as the arrows on the drive are completely visible (Y).

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Fig. 12:

1...2

6

5

2

4D

358 814-22

1

E

4

3

GN

GN

Install drive with oil container LC 2 in support bracket

Please note: • Set the delivery volume (see page 15 and 18), before removing the plug and screwing the lubrication unit in the support bracket.

• The oil container may only be bolted 1x.

• Oil may leak from the oil container during the following operations.

1. Label the oil container with the assembly and the expiration date.

2. Remove the oil container plug.

3. Screw the lubrication unit by hand into the support bracket (E).

4. Close the holder (D).5. Remove the protective

cap.6. Connect the connection

cable to the lubrication unit.

Please note: • After connecting the power cable and with supply voltage present, the LED indicators fl ash green (GN) in 5 s intervals.

• A fl ashing arrow icon appears in the display.

• The lubricating unit is ready for operation with the parameters previously set.

Please note:Only in pulse mode: After re-establishing the supply voltage a delivery process is carried out. During the delivery the drive and the LED indicators fl ash at 1 s intervals.

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Installation 33/54


8.5.4 Install adapter Set AS 2/C-100, -250

Fig. 13:

B

A

C

358 814-04

Install adapter Set AS 2/C-100, -250

1. Install the hose connector (C) in the lubricating pin (A).

2. Insert the lubrication pin (A) in the correct position in the bore of the drive head.

3. Secure the lubrication pin (A) with the lock washer (B).

4. Install the lubrication line.

Please note: • Only use 2 equal lubricant pins (do not mix adapter sets).Different lubricating pins cause unequal distribution through an uneven fl ow resistance.

• The difference in length of the lubrication lines should be < 20 mm.Different lubricating line lengths cause unequal lubrication distribution through an uneven fl ow resistance.

• The lubrication line must always be placed lower than the lubricating pin, otherwise the lubrication line runs empty (uncontrolled oil spillage, bubbles are formed in the hoses)

• Fill the lubrication line before commissioning, e.g. by repeatedly pressing the lubricating device (button in the PLC control) or using the special delivery PURGE (see page 23), until lubricant comes out of the lubrication pin.

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8.5.5 Install adapter Set AS 2/C-400, AS 2/C-700

Fig. 14: 358 814-06

4x

B

A

C

MD= 10NmSW10

Install adapter Set AS 2/C-400, AS 2/C-700


2. Remove the side cover of the drive head.


4. Secure the lubrication pin with the lock washer (B).

5. Install the lubrication line.6. Install the side cover of

the drive head.




• Fill the lubrication line before commissioning, e.g. by repeatedly pressing the lubricating device (button in the PLC control) or using the special delivery PURGE (see page 23), until lubrication comes out of the lubrication pin..

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Installation 35/54


8.5.6 Install adapter Set AS 2/R-300, AS 2/R-700

Fig. 15:

A

B

C

358 814-05

Install adapter Set AS 2/R-300, AS 2/R-700



3. Secure the lubrication pin (A) with the lock washer (B).

4. Install the lubrication line.





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Fig. 16:

B

A

C

358 814-07

4x

MD= 10NmSW10







the drive head.





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Fig. 17:

B

A

C

D

X

358 814-08

4x

MD= 10NmSW10






5. Install 2 O-rings (D) on the lubrication pin (A) so that they snap into the grooves (X).


the drive head.




• Fill the lubrication line before commissioning, e.g. by repeatedly pressing the lubricating device (button in the PLC control) or using the special delivery PURGE (see page 23), until lubrication comes out of the lubrication pin.

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8.6 Make the electrical connection to the product

WARNINGHigh electrical voltage!Risk of serious injury or death from electric shock.

Make sure the relevant system component is not under pressure or voltage before electrically connecting the product.

Secure the system against being switched on unintentionally.

NOTICEDamage to the product caused by faulty electrical connectionThe product can be damaged.

Electrical connection requires basic mechanical and electrical knowledge. The product may only be operated by qualifi ed personnel (see page 8). The voltage supply must comply with the connection data of the lubrication unit

(see “Technical data” on page 52).

• Choose control and sensor elements in accordance with EN ISO 13849. • Observe VDE specifi cation VDE 0100 in Germany or the appropriate specifi cations in the country of use.

Fig. 18: 358 814-10

43

2

1

Plug assignment (view of the drive socket)

Table 10: Plug assignment

Pin Cable color Signal

1 brown Voltage supply + V DC

2 white Signal output

3 blue Voltage supply GND

4 black Signal output Err

Signal states for the outputs OK and Err see Table 8 on page 25.

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8.6.1 PLC programming suggestions for evaluating the signal outputs

Fig. 19:

B06

B05

B08

B07 B04

B01 B09

B11 Q21out

&

and

B02&

and

&

and

Set

Reset

Q

latching relay

120 sec

50 sec

on delay

on delay

1

or

1inv

3in

2in

1

l1

A

l2

l3

in

1inv

B

1)

2)

358 814-13

PLC programming suggestion with one output signal

Fig. 20:

B02

B06

B05

B08

B07 B04

B01 B09

B10

B12

B03

B11 B13 Q2

Q11out

1out

&

and

&

and

&

and

Set

Reset

Q

latching relay

Set

Reset

Q

latching relay

1

120 sec

50 sec

or

on delay

50 secon delay

on delay

1

or

1

or

1inv

2in

1in

3

l3

l1

l2

in

1inv

A

B

1)

2)

3)

358 814-14

PLC programming suggestion with two output signals

A: PLC-terminal stripInputs

B: PLC-terminal stripOutputs

l1: Cable white, output OKl2: Cable black, output Errl3: Cable brown,

voltage supplyB05 No signal greenB06 No signal redB08 Cable break1): When using B02, l3:

Fault indication only when the lubrication unit is powered.

2): B01, B09 and B11 optional:error display only necessary when saving.

Q2: Output Q2 = High if: • Fault • Oil container empty • Cable break



l1: Cable white, output OKl2: Cable black, output Errl3: Cable brown,

voltage supply

B05 No signal green

B06 No signal red

B08 Cable break1): Connect output B04

directly to the input B13, if B11 B12 is not to be used.

2): When using B13, l3:Fault indication only when the lubrication unit is powered.

3): B11, B12 optional

Q1: Output Q1 = High if: • Oil container empty

Q2: Output Q2 = High if: • Fault • Cable break

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Fig. 21:

B02

B06

B05

B08

B07 B04

B01 B09

B10

B12

B03

B11 B13 Q3

Q2

Q11out

1out

1out

&

and

&

and

&

and

Set

Reset

Q

latching relay

Set

Reset

Q

latching relay

1

120 sec

50 sec

or

on delay

50 secon delay

on delay

1

or

1

or

1inv

2in

1in

3

l3

l1

l2

in

1inv

A

B

1)

2)

3)

358 814-15

PLC programming suggestion with three output signals



l1: Cable white, output OK

l2: Cable black, output Err

l3: Cable brown,voltage supply

B05 No signal greenB06 No signal redB08 Cable break1): Connect output B04

directly to the input B13, if B11 B12 is not to be used.

2): When using B13, l3:Fault indication only when the lubrication unit is powered.

3): B11, B12 optional

Q1: Output Q1 = High if: • normal function

Q2: Output Q1 = High if: • Oil container empty

Q3: Output Q2 = High if: • Fault • Cable break

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9 Start-up

9.1 First-time operation

CAUTIONUnforeseen movements, falling workpiece carrier

Risk of injury caused by unforeseen movements and falling objects. Make sure that the product has been installed correctly by qualifi ed personnel

(see page 8) before starting it up.

NOTICEMalfunctions due to incorrect assembly and start-upThe product may be damaged or its service life shortened.

Start-up requires basic mechanical and electrical knowledge. The product may only be operated by qualifi ed personnel (see page 8).

Operational malfunctions caused by unequal distribution of the lubricantThe product can be damaged; the service life may be adversely affected.

Only use 2 equal lubricant pins (do not mix adapter sets).Different lubricating pins cause unequal distribution through an uneven fl ow resistance.

The difference in length of the lubrication lines should be < 20 mm. Different lubricating line lengths cause unequal distribution through an uneven fl ow resistance.

Operational malfunctions due to lack of lubricantsThe product can be damaged; the service life may be adversely affected.

Ensure the lubrication lines are completely fi lled with lubricant before the product is put into operation.

• Before fi rst use or re-commissioning of a conveyor system, run a risk assessment in accordance with DIN EN ISO 12100.

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• Before initial commissioning ensure that there are no protruding or sharp-edged parts that may endanger personnel working or moving in the area.

• According to EU Machinery Directive 2006/42/EC, you must equip the transfer system with EMERGENCY STOP devices.

• The surfaces of engines and gearboxes can reach temperatures of over 65 °C under certain load and operating conditions. In these cases, you must comply with the appropriate design measures (protective measures) or the corresponding warnings of the applicable accident prevention regulations (UVV)!

• Make sure that all electrical connections are either used or covered. Make sure that all screw and plug-in connections are properly seated. All relevant protective covers must be installed.

• Continuous conveyors which are in motion or in operation may only be inspected and adjusted once all required safeguards are in place.

• Note EN ISO 13857 when you remove or replace safeguards and/or nullify a safety guideline.

• Test runs with open panels are only allowed if they are carried out by a competent person using tip switches and no interference through other switching elements exists.

• Only start up the product if all safety devices have been installed in the system and are functional.

• Start up the product only if it is installed completely.

9.1.1 Short description commissioning1. Mount the drive to the oil container (see page 31)2. Set delivery volume (see page 15 and 18)3. Mount the drive with the oil container to the support bracket (see page 32)4. Connect connection cable (see page 32)

• After connecting the power cable and with supply voltage present, the LED indicators fl ash green (GN) in 5s intervals.

• A fl ashing arrow icon appears in the display. • The lubricating unit is ready for operation with the parameters previously set.

9.2 Re-commissioning after a standstill periodFollow the steps for fi rst-time operation.

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10 Operation

CAUTIONHot surfaces of the electric motors in operation! Burns can result from the > 65 °C surfaces.

Provide for appropriate guard devices. Let the unit cool down at least 30 minutes before performing maintenance

and/or repair work.

10.1 Notices regarding operation

10.1.1 Wear • The principle of individual components leads to unavoidable wear. Structural measures and choice of materials are used to achieve functional reliability for the full service life. However, wear is also dependent on the operating, maintenance and ambient conditions at the place of use (resistance, contamination).

• Overloading conveyor sections can lead to failure of the conveyor and the premature failure of motors and gearboxes.

• If the pneumatically activated components are overloaded, it is not possible to guarantee their function.

10.1.2 Steps for reducing wearThe following measures will reduce wear: • Switch off the conveyor line when at standstill e.g. during breaks, at night, at weekends.

• Do not select a higher speed for the conveyor line than that required for the corresponding function.

• Avoid contamination due to abrasive media, reduce contamination by cleaning on a regular basis.

10.1.3 Environmental infl uences • Resistant to many conventional substances used in the manufacturing sector, such as water, oil, grease, and detergents. If you are unsure about resistance against certain chemicals such as test oil, doped oils, aggressive detergents, solvents, or brake fl uid, we recommend that you consult with your specialized Rexroth representative.

• Avoid prolonged contact with highly acidic or alkaline reacting substances. • Wear can increase signifi cantly in the case of contamination with abrasive media in the environment in particular; these include sands and silicates from construction work, for example, as well as from processes on the transfer system (e.g. welding beads, pumice dust, shards of glass, or loose and easily lost items). Under such conditions the maintenance intervals should be signifi cantly reduced.

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44/54 Maintenance and repair


• Resistance to media and contaminants does not mean that functional reliability can be guaranteed under all circumstances. – Liquids that thicken when they evaporate and become highly viscous or adhesive can lead to malfunctions. – Media that have a lubricating effect can reduce the drive power that is transmitted via friction if these media are displaced on systems with rollers.

In cases like these, particular care must be taken when planning the system and the maintenance intervals must be shortened appropriately.

11 Maintenance and repair


Disconnect the relevant system component before you perform maintenance and repair work.


High pneumatic pressure!Risk of serious injury or death.

Switch off the compressed air supply on the relevant system component before performing any maintenance or repair work.

All pneumatic cylinders must be depressurized (vented). Secure the system against being switched on unintentionally.

CAUTIONHot surfaces of the electric motors in operation!Burns can result from the > 65 °C surfaces.

Provide for appropriate guard devices. Let the unit cool down at least 30 minutes before performing maintenance

and/or repair work.

• Continuous conveyors which are in motion or in operation may only be inspected and adjusted once all required safeguards are in place.

• Note EN ISO 13857 when you remove or replace safeguards and/or nullify a safety guideline.

• Test runs with open panels are only allowed if they are carried out by a competent person using tip switches and no interference through other switching elements exists.

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Maintenance and repair 45/54


11.1 Cleaning and care

NOTICEFailure of the bearingsApplying grease-dissolving substances to the bearing points, e.g. when cleaning, leads to the failure of the bearings. There is a risk of damage to property, and the service life may be reduced.

Keep degreasers or aggressive cleaning away from the bearings! Clean the product only with a damp cloth.

Failure of the toothed beltApplying grease-dissolving substances to the toothed belt, e.g. when cleaning, leads to the failure of the toothed belt. There is a risk of damage to property.

Keep degreasers or aggressive cleaning away from the toothed belt. Clean the product only with a damp cloth.

11.2 InspectionPeriodically check the system status for possible errors by visual inspection of the LED indicators and the display (see page 25).

11.3 MaintenanceThe automatic lubrication unit LU 2 is maintenance free.

11.4 Replacement of worn partsRequired tools • Hex wrench (open-ended spanner) SW13, SW17, SW19. • Hex socket head cap screw SW4.

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11.4.1 Exchange oil container LC 2

Fig. 22:

1

RD

2

3

4B

C

E

D

358 814-23

2

RD

Disassemble oil container LC 2

Please note: • If the LED indicators are fl ashing red (RD) on the drive and LC appears in the display, the oil container is empty and must be replaced.

1. Remove the connection cable from the lubrication unit.

Please note:Only in pulse mode: After re-establishing the supply voltage a delivery process is carried out.

2. Open the holder (D).3. Unscrew the entire

lubrication unit out of the support bracket (E).

4. Loosen the union nut and remove the drive (B) from the empty oil container (C).

5. Dispose of the empty oil container in accordance with local regulations in your country for oil and grease waste.

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Maintenance and repair 47/54


Fig. 23:

5

43

358 814-24

GN

GN

6

6

7

2

1

Assemble oil container LC 2

Please note:The oil container may only be screwed in 1x.

Install drive on oil container LC 2 see page 31.

Install drive with oil container LC 2 in support bracket see page 32.

Please note: • After connecting the power cable and with supply voltage present, the LED indicators fl ash green (GN) in 5 s intervals.

• A fl ashing arrow icon appears in the display.

• The lubricating unit is ready for operation with the parameters previously set.

Please note:Only in pulse mode: After re-establishing the supply voltage a delivery process is carried out. During the delivery the drive and the LED indicators fl ash at 1 s intervals.

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11.4.2 Exchange battery LU 2

Fig. 24:

358 814-52

9

1

2.1

1)

8.2

2.28.1

B

3.2

ø2

CR24503V

4

6

5.2

7.1

“Click”

5.1

“Click”

3.1

A

D

E

C

7.27.2

Exchange battery LU 2

11.4.3 Replacement partsFor a list of spare parts, see MTparts, 3 842 529 770.

Please note: • If the LED indicators on the drive and the display are red, the battery is empty and must be replaced.

1. Remove the connection cable (A) from the lubrication unit.

2. Loosen the union nut and remove the drive (B) from the oil container (C).

3. Open and remove the battery compartment (D).1) No scope of delivery,

simultaneous loosening of the two locking mechanisms with any tool (e.g. welding wire, paperclip or 2 pens).

4. Remove the control board (E).

5. Exchange the battery (CR 2450, 3 V).

6. Install the control board.7. Install the battery

compartment.8. Install the Antrieb auf

den Ölbehälter (see page 31 + 32).

9. Connect the connection cable to the lubrication unit.

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Shutdown 49/54


12 Shutdown

The product is a component that does not need to be taken out of service. Therefore, the chapter in these instructions contains no information on the topic.

13 Disassembly and replacement


Disconnect the relevant system component before you perform maintenance and repair work.


High pneumatic pressure!Risk of serious injury or death.

Switch off the compressed air supply on the relevant system component before performing any maintenance or repair work.


Lifted loads may fall. Falling objects can result in serious injury (or even death).

Always use lifting equipment with suffi cient load bearing capacity (see shipping documents for product weight).

Check if the carrying straps are attached properly before lifting the product. The product must always be prevented from tipping over when lifting. During raising and lowering pay attention that nobody other than the operator

is in the danger zone.

13.1 Preparing the product for storage/further use • Only store the product on a fl at surface. • Protect the product from mechanical stress. • Protect the product from environmental infl uences such as dirt and moisture. • Pay attention to the ambient conditions, see page 53. • For products with mounted motor, support the product so that hanging-mounted engines will not be burdened.

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50/54 Disposal


14 Disposal

• The materials used are environmentally friendly. • They may be recycled or reused (if components are converted or replaced). Recyclability is ensured by the selection of materials and dismantling capacity.

• Careless disposal may pollute the environment. • Dispose of the product in accordance with the currently applicable national regulations in your country.

15 Upgrading and modifi cation

• Do not modify the product. • The Bosch Rexroth warranty only applies to the system as delivered and with approved upgrades. The manufacturer accepts no warranty claims for systems with unapproved modifi cations or upgrades.

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Troubleshooting 51/54


16 TroubleshootingError Possible cause Remedial action

No lubricant delivery Drive and oil container not properly bolted

Check assembly(see chapter “8.5.3 Install lubrication unit LU 2” on page 31)

• No lubricant delivery • Display: No plug symbol (cable break detection)

Faulty electrical connection Check electrical connection (see chapter “8.6 Make the electrical connection to the product” on page 38)

• LED indicator fl ashing red • Display: 0L

Counter pressure > 6 bar • Check lubrication points • Reduce counter pressure • Clear error message

press SET key for > 1 s

• LED indicator fl ashing red • Display: ut

Ambient temperature is too low ta < -20 °C

• Increase ambient temperature ta < -20 °C

• Clear error message press SET key for > 1 s

• LED indicator fl ashing red • Display: LC

Oil container empty • Replace oil container (see chapter “11.4.1 Exchange oil container LC 2” on page 46) • Control device setting

• LED indicator fl ashing red • Display: LC

Oil container not empty

Incorrect oil container entered or installed

• LED indicator fl ashing greenEmpty oil container

• LED indicator fl ashing red • Display: Er

• Device defective • Motor defective

Contact Bosch Rexroth customer service

Display: No display

Display: Lo Backup battery drive empty

If you are unable to fi x the error, you should contact us at one of the contact addresses which you can fi nd at www.boschrexroth.com.

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52/54 Technical data


17 Technical data

• For dimensions, see sales catalog TS 2plus, 3 842 531 138. • Voltage supply: Uin =9 - 30 V DC • Power consumption Ptyp = 0.24 W Pmax = 1.2 W

• Output voltage Uout, min = Uin - 2 V • Output current Iout, max = 500 mA • Permissible counter pressure 6 bar max. to 50 °C 4 bar max. from 50 to 60 °C

• Protection class IP65 • Acoustic emission: < 70 dB (A) • Weight LU 2with oil container LC 2 approx. 740 g

• Capacityoil container LC 2 250 cm³

• Connection cable M8 x 1 according to IEC 61076-2-104, halogen-free, length 5 m/10 m,

• Outer sheath material PUR black • Conductor cross section 4 x 0.25 mm² • Bending radius 44 mm min.

17.1 Storage period • Storage period drive/connection cable max. 2 years oil container LC 2 max. 1 year

• under storage conditions Protect against environmental infl uences, relative humidity 20% to 50% Ambient temperature 20 °C

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Technical data 53/54


17.2 Ambient conditions • The transfer systems are designed for stationary use in weather-protected areas. • Working temperature: +5 °C to +40 °C

–5 °C to +60 °C at 20% reduced load • Storage temperature –25 °C to +70 °C • Relative humidity 5% to 85%, non-condensing • Air pressure > 84 kPa corresponds to an altitude < 1400 m above sea level • Permissible load capacity of fl oor: 1000 kg/m2

• At altitudes > 1400 m, the load values of the electric drives are reduced by 15%. • Prevent mold, fungus, rodents, and other vermin. • Installation and operation in the immediate vicinity of industrial equipment with chemical emissions is not permitted.

• Do not install or operate near sources of sand or dust. • Do not install and operate in areas which are regularly jarred by high forces caused by, for example, presses or heavy machinery.

• Resistant to many common media used in production such as water, mineral oil, grease, and detergents. If you are unsure about resistance against certain chemicals such as test oil, doped oils, aggressive detergents, solvents, or brake fl uid, we recommend that you consult with your specialized Rexroth representative.

• Avoid long-term contact with acidic or basic reacting materials.

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Bosch Rexroth AGPO Box 30020770442 StuttgartGermanyFax +49 711 811–[email protected]

Subject to modifi cations3 842 358 814/2017-01

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Documents

3842358814 2017 01 NEW LU2 - dc-us.resource.bosch.com€¦ · precautions” and Chapter 3 “General notes on property and product damage”, and before a course of action or a required