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Page 101 

EN

KFG/KFGS pump malfunctions

Fault

Category

Possible cause

Rectification

Pump

 Agitator in 

grease reservoir does 
not rotate during the 
activated pump cycle 
(CONTACT mode).

Malfunction

 Mechanical damage,  

    e.g., motor defective

 Electrical connection interrupted

 • Replace pump 

  -   Loosen main line at outlet of pressure regulating valve.
  -  Loosen electrical connection. 
  -  Loosen three fastening screws. 
  -  Remove defective pump. 
  -   Mount new pump and connect lubrication 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 for damage. 

Pump does not 
function

 when the 

 key is pressed, 

although all electrical 
connections are ok.

Malfunction

 Electrical control has failed. 

 Pump drive/motor is defective.

  Lubricant level in reservoir is  

below minimum. 

 Agitator does not rotate.

• Check fuse
• Replace pump

• Fill lubricant reservoir to "max."

• Replace pump element 

 Note:

 metering is indicated by grooves.

15.1.8 Malfunctions on KFG/KFGS pump units

15. Operational and pump faults

K

F

G

S

K

F

G

Содержание KFG

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 115: ......

Страница 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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