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SKF KFG, Assembly Instructions Manual

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SKF KFG Assembly Instructions Manual Download Page 29

Page 29 

EN

Connector pin assignment (pump unit)

PIN     Description

  1 

  

  Voltage 24 VDC  

  2  

   

 

Not assigned 

  

  3 

  

 Ground   

  4 

   

Sig  Signal output

Connection diagram for energized W1 con-
trol with signal smoothing for NLGI Grade 2 
greases

Connection diagram for loating W1 control 

with signal smoothing for NLGI Grade 2 
greases (W1G = standard design)

W1G connector pin assignment (pump unit)

PIN 

     Description

  1 

  

com

  2  

  

 

nc

  

(pin 1 and pin 2 closed,  

 

   

reservoir empty)

  3 

    

Not assigned   

  4 

   

nc

  

(pin 1 and pin 4 closed,  

 

   

reservoir full)

K

F

G

Assembly instructions

1

2

3

4

+

  -     Sig        

1

2

3

4

com  nc         no

Summary of Contents for KFG

Page 1: ...EN KFG KFGS KFGC CAN bus for industrial use Assembly instructions acc to EC Dir 2006 42 EC for partly completed machinery with associated operating instructions Version 02...

Page 2: ...copyright SKF Lubrication Systems Germany GmbH re serves all rights including those to the photo mechanical reproduction duplication and dis tribution by means of special procedures e g data processi...

Page 3: ...4 VDC 31 Settings for progressive lubrication 32 4 5 3 2 Counter operation without system monitoring 32 4 5 3 3 Counter operation without system monitoring 33 4 5 3 4 Counter operation with system mon...

Page 4: ...1 6 3 3 2 Fill level monitoring 61 6 3 3 3 Monitoring lubrication cycle via piston detector 62 6 3 3 4 Monitoring signal cables for cable breakage and monitoring valves and piston detectors 62 6 3 3 5...

Page 5: ...1 12 6 Monitoring via piston detector 91 12 7 Monitoring via pressure switch 92 13 Shutdown 93 13 1 Temporary shutdown 93 13 2 Permanent shutdown 93 14 Maintenance 94 14 1 General information 95 14 2...

Page 6: ...on behalf of the manufacturer is the head of stan dardization see manufacturer s address Furthermore the following directives and harmonized standards were applied in the respective applicable areas...

Page 7: ...ace Indicator Use Danger danger of bodily injury Warning danger of damage to property and the environment Note Provides additional information Note Prompts an action Used for itemizing Points out othe...

Page 8: ...indicated above with regard to partly completed machinery Partly completed ma chinery which includes the product described herein is only intended to be incorporated into or assembled with other machi...

Page 9: ...ntion regulations and assembly conditions as a result of their training experi ence and instruction They are authorized to identify and perform necessary actions while avoiding any risks which may ari...

Page 10: ...10mg m Pressure dew point 7 C Water content max 7800 mg m Residual oil content max 25 mg m 1 6 Hydraulic pressure hazard The described product is pressurized during operation The product must therefor...

Page 11: ...nt isolating switch by thecustomer The unit must be grounded via a ground connection The customer must install ad equate overload protection for the power consumption of the motor To avoid electrostat...

Page 12: ...heir maximum permissible temperature Other media which are neither lubricant nor hazardous substance may only be fed after consultation with and written approval from SKF Lubrication Systems Germany G...

Page 13: ...on Systems Germany GmbH from the company s Service department 2 3 Approved lubricants Warning Only lubricants approved for the prod uct may be used Unsuitable lubricants can lead to failure of the pro...

Page 14: ...t during assembly operation maintenance and repair of centralized lubrication systems Leaks must be sealed off without delay Lubricant leaking from centralized lubrication systems is a serious hazard...

Page 15: ...elements 4 3 4 Pressure regulating valve 4 3 5 5 Conical head nipple 4 3 5 6 Electrical connection 4 5 7 General control unit Operating CAN bus display instructions 8 Pushbuttons Operating instruction...

Page 16: ...easily The fill level of the reservoir must be easily visible The unit is mounted in a vertical position Any assembly holes must be made according to the diagram on the following page Design specific...

Page 17: ...ons for assembly and accident prevention Warning Do not tilt the KFG S C grease lubrication pump unit The pump units are installed on the machine using three M8 screws with a minimum length of 20 mm F...

Page 18: ...26 226 11 KFGS5 5 1 10 210 637 205 226 15 75 0 4 200 0 4 9 0 4 2 1 Assembly holes 4 2 2 Mounting dimensions 1 KFGS _5 12 VDC or 24 VDC pump unit with control unit and supply volt age of 12 or 24 VDC K...

Page 19: ...a DIN 910 M20x1 5 5 8 screw plug with a DIN 7603 A20x24 Al washer 4 3 3 Installation of a pump element Pump units of the KFG KFGS und KFGC CAN bus series are generally delivered with pump elements in...

Page 20: ...in single line centralized lubrication systems M20x1 5 M14x1 5 KFG pump element with constant delivery rate without pressure regulating valve KFG pump element with constant delivery rate without press...

Page 21: ...used with manual grease presses to provide the lubrication system with adequate lubricant in case of power failure or a defective pump P A P M14 x 1 5 R R A Connections for pressure regulating valves...

Page 22: ...example to gain better access As an alternative the connection 2 can be used to mount a lubricant return or iller coupling see following page 2 1 Filler sockets lubricant return R A P R M14 x 1 5 P A...

Page 23: ...ng a illing cylinder 1 To do this remove the M20x1 5 screw plug 2 in the lubricant outlet and replace it with a iller socket part No 169 000 174 3 The caps 4 on the socket and illing cylinder must be...

Page 24: ...of 4 outputs 1 0 A with simultaneous operation of 2 outputs 1 25 A with operation of 1 output 1 5 A Modes of operation Single operation Parallel connection of multiple outputs while simultaneously in...

Page 25: ...e standard connections are presented below special designs may differ 4 5 2 1 Power supply 12 24 VDC 2 3 1 L 1 KFG DC 2 3 X1 M L 4 5 2 2 Power supply 90 264 VAC 2 3 1 KFG AC X1 1 2 3 M DC AC 1 C6A F L...

Page 26: ...ad no lamp load signal lamp 2 Cable socket see Accessories Chapter 17 W1 connector pin assignment pump unit PIN Description 1 Supply voltage 2 Signal output W1 3 Not assigned 4 Not assigned Socket con...

Page 27: ...instructions on page 16 Warning The W2 ill level switch is not suit able for greases NLGI grade 2 Note Customer speciic designs are available in addition to the two standard designs shown In this case...

Page 28: ...connection diagram for floating and energized contacts W1_smooth connection same as W2 control W1_smooth isolation of supply voltage potentials between ill level monitoring and pump voltage The follow...

Page 29: ...h signal smoothing for NLGI Grade 2 greases Connection diagram for loating W1 control with signal smoothing for NLGI Grade 2 greases W1G standard design W1G connector pin assignment pump unit PIN Desc...

Page 30: ...valve 230 VAC Input voltage 230 VAC Coil voltage 205 VDC Rated output 26 W Rated current 0 13 A ON time 100 at 35 C pressure regulating valve Set pressure 200 bar Protection class IP 65 Plug in connec...

Page 31: ...n the pump unit design an addi tional plug for ill level control and or a plug for a pump side pressure relief valve single line centralized lubrication system can be inte grated into the pump housing...

Page 32: ...me is time dependent Connector pin assignment PIN Code Assignment 1 M Supply voltage potential 0 V GND 2 L Supply voltage potential 3 L MK Machine contact potential Programming cPA tCO COP OFF see Cha...

Page 33: ...W SL1 2 4 W BK BK ZS Programming cPA tCO COP CS One pulse is counted each time the operating voltage is switched on when the machine contact is closed in counter operation Control using machine pulses...

Page 34: ...lized lubrication system Programming tPA tCO COP OFF 1 BN KFGS F 2 3 4 5 6 7 X1 RD BK BU PK VT GN DK SL2 2 4 W M L Industrie SL1 2 4 W 1 BN KFGS F 2 3 4 5 6 7 X1 RD BK BU PK VT GN DK SL2 2 4 W SL1 2 4...

Page 35: ...wer supply 12 24 VDC using a cubical plug Connector pin assignment per DIN EN 175 301 803 You can ind technical data and the order number of the M12x1 circular connector mating part for circular plug...

Page 36: ...A tCO COP OFF 24 VDC X2 1 2 3 SL2 4 BU BK SL2 2 4W Connector pin assignment in timer operation PIN Code Assignment 3 SL2 Fault indicator light 4 SL2 Fault indicator light 4 5 3 10 Connectivity for tim...

Page 37: ...Input voltage 24 VDC Rated output 26 W Rated current 1 2 A ON time 100 Protection class IP65 pressure regulating valve Set pressure 200 bar Plug in connection per DIN EN 175301803 Pressure relief valv...

Page 38: ...tion 1 L1 Main machine switch ON 2 N 3 Not assigned PE Protective earth 1 External control device relay contact pump on Connector pin assignment per DIN EN 175 301 803 The Timer operation with system...

Page 39: ...ductor coloring 1 BN Brown 2 WH White 3 BU Blue 4 BK Black 3 4 1 2 Socket connection per EN60947 5 2 4 5 5 2 Connections for system monitoring Connector pin assignment in timer operation PIN Code Assi...

Page 40: ...sensors 4 5 6 1 Power supply 12 24 VDC 2 4 5 3 1 6 7 Connector pin assignment for power supply PIN Color code Function 1 BN Brown 31 M 2 RD BK Red black 15 3 BU Blue MC CS4 4 PK Pink MC CS4 5 BK Blac...

Page 41: ...Connection for reversing valve piston detector max 6 connections Accessories for reversing valve piston detector Description Order No Cable harness with socket approx 2 m 997 000 734 3 4 1 2 Connecto...

Page 42: ...with the maximum equipment level 6x M12x1 circular connectors for operating a progressive feeder system distributed in four lubrication zones A B C CS Piston detectors V Reversing valves 2 4 5 3 1 6 7...

Page 43: ...lar connectors for operating a progressive feeder system multiple zones not used Piston detector Assignment of 7 pin circular connector 2 4 5 3 1 6 7 A B C Legend for connection diagram example with m...

Page 44: ...ctional solenoid valve The 5 4 directional control valve is intended for use in progressive feeder lubrication systems and in the industrial sector It possesses an input which can be switched to one o...

Page 45: ...nt Remove main lines on unit Allow pump to run until lubricant without bubbles is discharged at the straight con nector on the pump element Mount main lines Allow pump to run until grease can be seen...

Page 46: ...ovide important key data such as designa tion and material description or customer number To avoid loss of this data in case the rating plate becomes illegible these characteristics should be entered...

Page 47: ...structions acc to 98 37 EC Annex II B for partly completed machinery Operating instructions associated with assembly instructions according to EC Dir 2006 42 EC for partly completed machinery KFG KFGS...

Page 48: ...observed and applied 2 Lubricants Warning The information on lubricants listed in Chapter 2 Lubricants of the assembly instructions also applies without restric tions to these operating instructions D...

Page 49: ...ing storage conditions 3 1 Lubrication units Ambient conditions dry and dust free surroundings storage in well ventilated dry area Storage time max 24 months Permissible humidity 65 Storage temperatur...

Page 50: ...are contained later in this chapter 4 2 Assembly procedure for KFG S C pump units Assembly must be performed in accordance with the included assembly instructions and the additional information instru...

Page 51: ...ee lubricant outlets for installing a maxi mum of three pump elements One pressure regulating valve can be attached to each pump element When used in single line systems a pressure relief valve is als...

Page 52: ...ervoir pump units with an integrated control unit Parameters for interval times timer interval pulses counter and pump cycle times con tact can be entered through the control panel A piston detector i...

Page 53: ...n Chapter 4 in the assembly instructions The control unit s comprehensive monitoring functions allow potential faults to be detected early This includes among other things monitoring the ill level in...

Page 54: ...nit with 6 kg lubricant reservoir KFG pump unit without integrated control unit with 2 kg lubricant reservoir 5 6 Images of pump units KFGS pump unit with integrated control unit and 2 kg lubricant re...

Page 55: ...ion point being supplied In progressive systems with a master feeder and secondary feeder the lubricant coming from the pump unit is delivered to the master feeder The master feeder distributes the lu...

Page 56: ...a backup in case of voltage failure Non volatile memory with PIN code protection Connectivity for inductive piston detector to monitor the feeder function Connectivity for external pushbutton Internal...

Page 57: ...ion zone The pump can only provide adequate lubrica tion to one lubrication zone at a time so it must be ensured that only one valve is opened during operation This is handled by the control unit in a...

Page 58: ...control unit by the machine depending on how long it has been running This provides two different means of control timer mode and counter mode In semi automatic mode the user sets the interval between...

Page 59: ...in hours minutes and seconds The pump cycle time for units with W1 ill level control can also be set in pulses i e the number of agitator revolu tions Control using machine pulses Counter mode load de...

Page 60: ...time for each zone is based on time or pulses and is conigured by entering the time in hours minutes and seconds or a number of pulses corresponding to revolutions of the pump s agitator The lubricati...

Page 61: ...tion is issued if for example the ill level in the lubricant reservoir falls below the min mark It only makes sense to deactivate system monitoring if the functions mentioned above cannot be used beca...

Page 62: ...ra tion In contrast with the KFGS pump unit the KFGC CAN bus design can repeat the lubrication cycle as often as desired If the speciied number of pulses strokes is reached during the repeat lubricati...

Page 63: ...utputs for short circuits The control unit is capable of detecting short circuit faults on the outputs In such cases the output is switched off which idles the cor responding valve and a fault notiica...

Page 64: ...s power the most recent status data remains in the FRAM When the control unit is turned on again it reads the saved data and the lubrica tion process continues where it left off unless the coniguratio...

Page 65: ...and passed to the lubrication points This is performed during or after the pump cycle time depending on the type of distributors used prelubrication or relubrication distribu tors After metering is co...

Page 66: ...emaining lubrication times Recording of fault notiications diagnostics memory Data backup in case of voltage failure Non volatile memory with PIN code protection Connectivity for pressure switch Fill...

Page 67: ...ems with directional solenoid valves Directional solenoid valves can be used to create a single line system with up to four lubrication zones The system can be equipped with or without functionality t...

Page 68: ...sure relief valve is opened When multiple lubrication zones are used the corresponding inlet valve is closed at the same time The duration of the pump cycle time is a time value conigurable in hours m...

Page 69: ...arting and switching off the pump Opening and closing the valves of the lubrication zones The interval time and pump cycle time are the most important parameters for controlling these processes They c...

Page 70: ...trol unit actuates the zones as described in the preceding section The pump cycle time for each zone is time dependent and is conigured by entering a time value in hours minutes and seconds The pump c...

Page 71: ...nsor sends a signal to the control unit if the lubricant level reaches the min mark The control unit then generates a fault notiication see Chapter 15 7 3 4 2 Pressure build up monitoring single line...

Page 72: ...ed If the pressure switch is not found the control unit assumes a cable has been broken In this case the lubrication zone is deactivated until the pressure switch fault is resolved On a system without...

Page 73: ...s continues where it left off unless the coniguration has been changed All faults detected by the lubrication system s monitoring functions are also given a time stamp and stored persistently in the c...

Page 74: ...ants cannot be mixed as mixing may result in damage and necessitate costly and complicated cleaning of the product centralized lubrication system It is recommended that an indication of the lubricant...

Page 75: ...lues and operating status PAUSE LED Interval time CONTACT LED Display contact time pump operation 1 CS LED Monitors system function via an external piston detector CS Cycle Switch piston detector 2 PS...

Page 76: ...n PAUSE mode The control unit is functioning as a counter and is currently in PAUSE mode The control unit is functioning as a timer and is currently in a pump cycle CONTACT The control unit is functio...

Page 77: ...ing pump cycle The values shown after this are the number of hours the control unit has operated The system pressure is moni tored by the pressure switch during the pump cycle The control unit is curr...

Page 78: ...ed off Monitoring by pressure switch cannot be activated on progressive systems COP CS monitoring is active COP OFF monitoring is switched off Operating voltage is present on pump unit and control uni...

Page 79: ...and deleted Switch on the display in display mode Call up next parameter in programming mode Increase displayed value by 1 Switch on the display in display mode Call up last parameter in programming m...

Page 80: ...D Lights up when communication with the CAN network has been successfully established Yellow CS MC LED Lights up briefly when the control unit detects a signal edge at an input from a piston detector...

Page 81: ...le Symbol Description Function IrDA interface Infrared service interface Read stored status data and fault notifications Configure the control unit via PC DK key Trigger interim lubrication Halt lubri...

Page 82: ...g status is shown Example Timer operation pause Press briefly 2 Display remaining interval time for current lubrication cycle Example 1 h 3 Display pre set total interval time Example 2 6 h factory se...

Page 83: ...ay operating hours 10 11 Example 1st part of 2nd part of total value total value Total value 00533 8 h Write down Maximum value 99999 9 h 12 Display fault hours 13 14 Example 1st part of 2nd part of t...

Page 84: ...r pause in timer operation Press briefly PAUSE LED flashes confirm code 3 Interval time 1 h factory setting display in hours Press briefly 4 Set new value Example 6 8 h 6 h 48 min 5 Display next param...

Page 85: ...Continuation of Change lubrication interval times table Step Key Display 7 Set new value 8 Press briefly confirm new value 9 Changes are written to memory the values are activated and Press for more t...

Page 86: ...ing Press briefly 5 Press either until or Monitoring via piston Monitoring via Pressure detector CS LED flashes switch PS LED flashes 6 Press briefly Confirm new setting 7 New settings are written to...

Page 87: ...th external electrical pulse generator Values in pulses 4 Display pump cycle time in timer operation Press briefly to confirm counter operation 5 Change from pump cycle time to counter operation speci...

Page 88: ...until Warning Do not enter 321 6 Press briefly Confirm new code 7 New code is written to memory Press for more than 2 s and the display clears 11 5 Change access code This factory default code is now...

Page 89: ...1 Interval time 0 1 h to 99 9 h Pump cycle time 0 1 min to 99 9 min Pulses 1 to 999 Display ranges Function Display range Fault hours 0 1 h to 99999 9 h Operating hours 0 1 h to 99999 9 h 1 For the p...

Page 90: ...olutions etc A lubrication is triggered once the set number of pulses cPA is reached Set cPA und tCO in programming mode 12 3 No system monitoring In this operating mode the lubrication cycle is contr...

Page 91: ...be sent to the factory for rework 12 6 Monitoring via piston detector Only possible for centralized lubri cation systems with progressive feeders For greases up to NLGI Grade 2 The piston detector mo...

Page 92: ...nt to the KFGS control unit when the set pressure is reached The following monitoring setting must be activated in programming mode COP PS see Chapter 11 3 For single line centralized lubrication syst...

Page 93: ...ommission the product follow the in structions in the Chapter Assembly 13 Shutdown 13 2 Permanent shutdown If the product will be permanently shut down the local regulations and laws regarding the dis...

Page 94: ...using mild cleaning agents that are compatible with the product s materials non alkaline non soap For safety reasons the product should be disconnected from the power supply and the hydraulic and or...

Page 95: ...ditions The customer is therefore responsible for determining and observing the maintenance intervals on its own All work beyond this scope must be performed by authorized SKF Service establishments 1...

Page 96: ...instructions contained in these operating instructions If necessary please con tact an SKF service office In conjunction with lubrication reservoir filling KFGS KFGC CAN bus Check of basic function o...

Page 97: ...ough it requires system monitoring 15 1 2 Display faults Start the display mode with one of the two keys Press the key until you reach the fault notiication see following table 15 1 3 Delete fault not...

Page 98: ...lights up and remains constant LED flashes Fill level in the reservoir sinks to the level of the pre warning sensor only on systems equipped and configured with this functionality Insufficient number...

Page 99: ...locks of three digits each by calling up the parameter Fh see Chapter 6 The maximum reading that can be displayed is 99 999 9 hours The smallest recordable interval is 0 1 hours 6 minutes The memory c...

Page 100: ...cond lubrication cycle begins in block operation As soon as a signal is received from the piston detector block operation is aborted and the normal lubrication cycle starts with a pause A total of thr...

Page 101: ...rication line and electrical cable Perform commissioning and functional inspection Be sure the interval and contact times are correct Check or replace fuse Check electrical connections Check cable set...

Page 102: ...element and operate pump using the key until grease discharges from outlet on housing Replace pump element Note metering is indicated by grooves If necessary adjust lubricant to work properly at lowe...

Page 103: ...in the FRAM Malfunctions are indicated by a lashing LED light At the same time the fault notiication is stored in the FRAM 15 2 5 Read faults All fault notiications generated during op eration are sto...

Page 104: ...s must always be remedied immediately LED lights up and remains constant LED flashes The fill level in the reservoir sinks to the level of the pre warning sensor only on systems equipped and configure...

Page 105: ...ediately refill with lubricant see Chapter 4 4 page 22 change pump element if necessary Replace the cable Pressure build up fault Malfunction Lubrication line defective Pressure switch defective Press...

Page 106: ...ckage and lubricant for feedability Let pump unit cool down Motor current fault Malfunction Partial or total blockage of motor shaft and or agitator Check the agitator for freedom of movement Check wh...

Page 107: ...or operation according to the intended use in machinery KFG KFGS KFGC CAN bus 12 24 VDC Functional Extra Low Voltage Protective Extra Low Voltage PELV Disconnect the unit for insulation and voltage in...

Page 108: ...C to 40 C S1 continuous operation at 40 C to 60 C Run time 0 to 10 min minimum interval time 4 x run time 20 ON time Run time 10 to 15 min minimum interval time 2 h Data universally applicable to KFG...

Page 109: ...2 4 A 1 5 A 9 A 10 A 2 3 24 VDC 24 VDC 1 25 A 1 2 5 A 4 5 A 7 5 A 2 3 Fill level switch W1 NLGI 2 Fault notification via pulse Fill level switch W1_smooth NLGI 2 Fault notification via energized cont...

Page 110: ...5 A Single operation Parallel connection of multiple outputs while simultaneously increasing output current Signal inputs Type Connectivity All types digital solid state input short circuit proof Swi...

Page 111: ...990 372 M12x1 plug straight with 5 m cable 4x 0 25 mm2 protection class IP 68 mounted 179 990 600 M12x1 angle plug with 5 m cable 4x 0 25 mm2 protection class IP 68 mounted 179 990 601 Cable socket a...

Page 112: ...ssure piston detector signal A double pin plug with a special cable adapter is required for this application Accessories Description Data Order No M12x1 circular connector with cable for connecting to...

Page 113: ...e extension and pulse monitoring Piston distributor for single line systems EXZT2A07 E Pulse generator counter with adjustable interval time interval time extension pressure build up monitoring fill l...

Page 114: ...e systems IGZ51 20 S3 E Pulse generator counter with adjustable interval time interval time extension monitoring of pressure build up and reduction adjustable delay time and connectable non volatile m...

Page 115: ......

Page 116: ...se as described in these as sembly instructions with associated operating instructions If assembly operating instruc tions are supplied together with the products they must be read and followed Not al...

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