SKF KFG Assembly Instructions Manual
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SKF KFG Assembly Instructions Manual

Piston pump aggregate for vehicle lubrication
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KFG; KFGS; KFGL; KFGC (CAN bus)
for vehicle lubrication
ax
in
Use hard grease NLGI-2 only !
KFG
Version 05
max
max
KFGS
KFGL
Assembly instructions
for partly completed machinery with associated operating instructions
max
1
2
3
KFGL-MonoFlex
acc. to EC Dir. 2006/42/EC
max
1
2
3
KFGC
EN

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  • Page 1 KFG; KFGS; KFGL; KFGC (CAN bus) Assembly instructions acc. to EC Dir. 2006/42/EC for partly completed machinery with associated operating instructions for vehicle lubrication Use hard grease NLGI-2 only ! KFGS KFGL KFGL-MonoFlex KFGC Version 05...

  • Page 2: Pump Unit Ill Level Control Monitoring, Order Code 1 And

    Page 2 Notes Service Masthead © SKF Lubrication Systems Germany GmbH If you have technical questions, please contact These assembly instructions with associated op- This documentation is protected by copyright. the following addresses: erating instructions according to EC Machinery SKF Lubrication Systems Germany GmbH...

  • Page 3: Table Of Contents

    1 and 2 4.11.4 Pump unit ill level control 4.5.1 General conditions for 3. Overview electrical connections 4.12 Lubrication line connection KFG power supply and connections 30 4. Assembly 4.13 Lubrication line arrangement 4.6.1 KFG power supply General information 4.14 Progressive system ventilation 4.6.2 External control units...
  • Page 4 8. Commissioning progressive systems General commissioning General information Functional description for progressive Disclaimer of liability systems with a KFG pump unit 6.1.1 Pump element 9. KFGS control unit 2. Lubricants 6.1.2 Pressure regulating valve Display and control elements Progressive system with a...
  • Page 5 Table of contents Page 5 10. KFGL control unit 14. Operational and pump faults 15. Technical data 10.1 Display and control elements 14.1 Operational malfunctions of control screen 14.1.1 General information 10.2 Display and control menu 14.1.2 Malfunctions on pump units 16.
  • Page 6 Page 6 EC Declaration of Incorporation according to Machinery Directive 2006/42/EC, Annex II Part 1 B The manufacturer SKF Lubrication Systems Germany GmbH ,Plaint Hockenheim, 2. Industriestraße 4, DE - 68766 Hockenheim hereby declares that the partly completed machinery: Designation:...

  • Page 7: Explanation Of Symbols And Signs

    Explanation of symbols Page 7 Explanation of symbols and signs You will ind these symbols, which warn of Instructions placed directly on the machines/ speciic dangers to persons, material assets, or grease lubrication pump units, such as: the environment, next to all safety instructions Arrow indicators Labels for luid connections You are responsible! in these operating instructions. Please heed these instructions and proceed must be followed and kept in fully legible Please read the assembly and operating...

  • Page 8: Documentation Overview

    Note that the assembly instructions 951-180-004-EN form part of the product and must accompany the product if sold to a new KFG; KFGS; KFGC (CAN bus) for owner. vehicle lubrication 951-170-204-EN The described product is manufactured in ac-...

  • Page 9: Intended Use

    Assembly instructions Page 9 Intended use Authorized personnel Pump units of SKF's KFG, KFGS, KFGL and maximum permissible temperature. Only qualified technical personnel may install, KFGC series are used to supply centralized lu- operate, maintain, and repair the products de-...

  • Page 10: Electric Shock Hazard

    Page 10 Assembly instructions Hydraulic pressure hazard Electric shock hazard Electrical connections for the described product Dangerous contact voltages may occur The described product is pressurized may only be established by qualified and on the unit if the protective earth during operation.

  • Page 11: Explosion Protection Information

    Only the pump models tested andap- The unit must be grounded via a ground The user must make sure through the proved by SKF Lubrication Systems connection. The customer must install ad- choice of the lubricant to be delivered that...

  • Page 12: Lubricants

    SKF Lubrication Systems Germany GmbH . quantity of lubricant is provided to the SKF Lubrication Systems Germany GmbH con- lubrication point. The lubrication point...

  • Page 13: Approved Lubricants

    You can request an overview of the lubricant accidental mixing of lubricants. tests offered by SKF Lubrication Systems The product described here can be operated Germany GmbH from the company's Service using lubricants that meet the specifications in the technical data.

  • Page 14: Lubricants And The Environment

    Page 14 Assembly instructions Lubricants and the environment Lubricant hazards Warning! Danger! Lubricants are a hazardous substance. The Lubricants can contaminate soil and Centralized lubrication systems must al- safety instructions on the lubricant's safety bodies of water. Lubricants must be ways be free of leaks.

  • Page 15: Overview

    Assembly instructions Page 15 3. Overview Unit components Unit components Pos. Description Chapter 1 Assembly holes 4.2.2-4.2.4 2 Lubricant reservoir 4.2.3-4.2.4 3 Fill level monitoring 4.11-4.11.4 4 Lubricant filling 4.4-4.4.3 5 Pump element 4.3-4.3.3 6 Pressure regulating valve 4.3.4 7 Electrical connection 4.5-4.5.1 8 Control port assignments 4.6-4.9...

  • Page 16: Assembly

    Any assembly holes must be made assembly work. unit of the KFG, KFGS or KFGL series to oper- according to the diagram on the following ate up to three independent zones. page. Design specifications and conditions of...

  • Page 17: Minimum Clearance Height For Installation

    Warning! Warning! The minimum clearance height for installation On the pump units' electrical connections, Do not tilt or drop the KFG (S) (L) (C) depends on the reservoir design. ensure that appropriate measures pre- grease lubrication pump unit! vent interference between signals due...

  • Page 18: Mounting Diagram

    Page 18 Assembly instructions 4.2.2 Mounting diagram Mounting diagram, Fig. 1 2 kg/6 kg 10 kg/15 kg/20 kg Mounting diagram ± Pump Dim. A Dim. B size [mm] [mm] 10 kg 15 kg 342.5 Ø 9,0 20 kg 432.5 Use hard grease NLGI-2 only !

  • Page 19: Mounting Dimensions

    Assembly instructions Page 19 4.2.3 Mounting dimensions, 12 VDC / 24 VDC design without control unit Assembly dimensions, Fig. 2 Flange mounting view 10 kg / 15 kg / 20 kg Ø9 Use hard grease NLGI-2 only ! Flange mounting view 2 kg / 6 kg 2 kg / 6 kg 10 kg...

  • Page 20: Mounting Dimensions

    Page 20 Assembly instructions 4.2.4 Mounting dimensions, design with control unit, 12 VDC / 24 VDC Assembly dimensions, Fig. 3 Flange mounting view 10 kg / 15 kg / 20 kg Ø9 Use hard grease NLGI-2 only ! Flange mounting view 2 kg / 6 kg...

  • Page 21: Pump Elements

    Page 21 KFG (S) (L) (C) pump element series Layout of the pump elements, Fig. 4 KFG pump units can be equipped with up to A grease return or a filler socket can be at- three pump elements. tached in place of a pump element. A screw plug (DIN 910-M20x1.5-5.8) with sealing ring...

  • Page 22: Pump Elements With Spring-Return Pistons

    Page 22 Assembly instructions 4.3.2 Pump elements with spring-return pistons When ordering pump elements, the required Pump elements with spring-return pistons delivery rate must be specified, as well as the Delivery rate Number of grooves Max. permiss. oper. pressure Order No. design type (spring return pistons/ positively /min] [bar] driven pistons).

  • Page 23: Assembly Of A Pump Element With Spring Return Pistons

    Assembly instructions Page 23 4.3.3 Assembly of a pump element with spring return pistons • Turn off pump unit. Assembly, spring-return pump element, Fig. 7 • Unscrew and remove screw plug (KFG1.128) Then perform the following: • Loosen and remove pressure regulating valve (2) (or lubrication line (3) on an already mounted pump element (1).

  • Page 24: Pump Elements With Positively Driven Pistons

    Page 24 Assembly instructions 4.3.4 Pump elements with positively driven pistons 4.3.3 Assembly of a pump element with positively driven pistons see Fig. 9 Pump elements with positively driven pistons Delivery rate Max. permiss. oper. pressure Labeling Order No. • Turn off pump unit. /min] [bar] •...
  • Page 25 Assembly instructions Page 25 the housing bore with a bar magnet (or Assembly, positively driven pump element, Fig. 9 taper-nose pliers). Section A • Section C Carefully pull the piston (6) out of the new pump element (1) • Coat the bore of the pump element lightly Section C with grease •...

  • Page 26: Pressure Regulating Valve

    Page 26 Assembly instructions 4.3.4 Pressure regulating valve Pressure regulating valve Pressure regulating valve, Fig. 10 Pressure regulating valve without A pressure regulating valve (1) protects the lubricant nipple entire lubrication system against excessive Tube Ø Cracking pressure Order number system pressure.

  • Page 27: Lubricant Illing

    Assembly instructions Page 27 4.4 Information on lubricant illing Pressure regulating valve Pressure regulating valve with Only ill using clean lubricant and an Filling, Fig. 12 T connector output appropriate illing device. Contaminated Tube Ø Cracking pressure Order number lubricants can result in severe system [mm] [bar] malfunction.

  • Page 28: Filler Coupling

    Page 28 Assembly instructions 4.4.2 Filler coupling 4.4.3 Filling cylinder As an alternative or in addition to the conical When used at very low temperatures, the pump unit can optionally be illed via one of head nipple (1) the unit can also be itted with a iller socket (part No. 995-000-705) (2) for the lubricant outlets using a illing cylinder (1). illing by means of a iller pump. This is done by removing the screw plug A corresponding coupling socket (part No.

  • Page 29: Electrical Power Supply

    Assembly instructions Page 29 Electrical power supply 4.5.1 General conditions for electrical connections KFG; KFGS; KFGL; KFGC, General conditions for electrical connections Warning! Compare the operating voltage with the speciications on the rating plate. Nominal Power Power Pump Max. Voltage consumption consumption starting current...

  • Page 30: Kfg Power Supply And Connections

    KFG power supply and connections 4.6.1 KFG power supply 4.6.2 External control units The KFG pump unit is available in the voltage designs 12 VDC and 24 VDC. The electrical The external control units listed in KFG power supply, Fig. 16...

  • Page 31: Kfgs Power Supply And Connections

    Assembly instructions Page 31 KFGS power supply and connections 4.7.1 KFGS power supply With integrated IG502 control unit KFGS power supply, Fig. 17 Connector pin assignment The electrical connection is a 7-pin plug-in connector on the base of the pump unit. Color code Conductor coloring Brown...

  • Page 32: Without System Monitoring

    Page 32 Assembly instructions Programming: - Chapter 9 of assembly instructions 4.7.2 Connectivity 4.7.3 Connectivity Counter operation without system monitoring Counter operation with system monitoring Control using machine pulses (Counter mode = load-dependent lubrication) KFGS connection, Fig. 19 KFGS connection, Fig. 18 The duration of the interval time is determined KFGS...

  • Page 33: Connectivity Timer Operation With System Monitoring

    Assembly instructions Page 33 Programming: 4.7.4 Connectivity 4.7.5 Connectivity - see Chapter 9 of with assembly instructions Timer operation without system monitoring Timer operation with system monitoring Timer mode KFGS connection, Fig. 20 KFGS connection, Fig. 21 In timer mode, the interval time is determined KFGS...

  • Page 34: Kfgl Power Supply And Connections

    Page 34 Assembly instructions KFGL power supply and connections 4.8.1 KFGL power supply With integrated LC502 control unit Connector pin assignment KFGL power supply, Fig. 22 The KFGL pump unit can be itted with a ill Color code Conductor coloring level switch of one of the following types for indication of the “Minimum” ill level: Brown RD-BK...

  • Page 35: Kfgl Proflex For Progressive Centralized Lubrication Systems

    Assembly instructions Page 35 4.8.2 KFGL ProFlex for progressive centralized lubrication systems KFGL ProFlex, Fig. 23 Power supply Pin 1: OV (-) Pin 2: 12/24 VDC (+) Error output (Fault) Pin 3: Fault notification (-) Pin 4: Fault notification (+) Input 3 (In 3) Pin 5: External DK (-) Pin 6: External DK (+)

  • Page 36: Kfgl Monoflex For Single-Line Lubrication Systems

    Page 36 Assembly instructions 4.8.3 KFGL MonoFlex for single-line lubrication systems KFGL MonoFlex, Fig. 24 Power supply Pin 1: OV (-) Pin 2: 12/24 VDC (+) Error output (Fault) Pin 3: Fault notification (-) Pin 4: Fault notification (+) Input 3 (In 3) Pin 5: External DK (-) Pin 6: External DK (+) Output 1 (Out 1)

  • Page 37: Kfgc Power Supply And Connections

    Assembly instructions Page 37 KFGC power supply and connections 4.9.1 Power supply With integrated LC-CAN5000 control unit Connector pin assignment of power supply KFGC power supply, Fig. 25 In this version, the electrical connection is a Color code Function 7-pin plug-in connector on the base of the Brown 31 m pump unit.
  • Page 38 Page 38 Assembly instructions KFGC CAN connector, Fig. 26 M12x1 connector, Fig. 27 Accessories for reversing valve/piston detector Description Order No. Wiring harness for pressure relief valve on pump side, CAN bus connection, Reversing valve/piston approx. 0.4 m 179-990-847 plug type DEUTSCH detector connection DT04-3P-L012 (max.

  • Page 39: Connectivity

    Assembly instructions Page 39 4.9.2 Connectivity Example of the connection of four reversing Maximum configuration example, Fig. 28 valves and four piston detectors for units with maximum configuration (6x circular connectors M12x1 available) for the operation of a pro- gressive feeder system, divided into four lubri- cation segments Assignment of the 7-pin Assignment of the...
  • Page 40 Page 40 Assembly instructions Example of the connection of a piston detector Minimum configuration example, Fig. 29 or machine contact and a reversing valve on a unit with minimum configuration (without circular connector M12x1) for operation of a progressive feeder system, no division into Assignment of the CAN bus connector Assignment of the 7-pin circular connector lubrication segments.

  • Page 41: Pressure Relief Valve With Integrated Pressure Regulating Valve

    Assembly instructions Page 41 4.10 Pressure relief valve with integrated pressure regulating valve (for single-line systems with VR distributors) Pressure relief valve/pressure regulating valve, Fig. 30 Technical data Pressure relief valve 12 VDC / 24 VDC Input voltage ... 12 VDC 24 VDC Hydraulic Rated output .

  • Page 42: Fill Level Monitoring

    Switching capacity, max. . . 0.6 W falling below the minimum, thus preventing any Switching voltage, max..24 VDC damage to the KFG pump units which could Switched current, max..25 mA; result from that.

  • Page 43: Order Code 2 (W1G)

    The following functions are integrated for the Function ....Dry (poten- tial-free) or KFG pump unit with signal smoothing: non-dry contact,  Possible isolation of power supply voltages depending on...
  • Page 44 Assembly instructions 4.11.3 KFG connection with ill level Type: W1G Type: W1 monitoring, order code 1 and 2 The standard model of the KFG pump unit is block diagram W1 not fitted with fill level monitoring. Function KFG models with fill level monitoring need to...

  • Page 45: Lubrication Line Connection

    "min" mark, the lubrication process is stopped and the fault notiication "FLL" is issued on the as can occur especially in progressive central- could hinder lubricant flow and introduce con- ized lubrication systems, SKF cutting-sleeve taminants into the lubrication line system. display. screw unions conforming to DIN 2353 can be Lubrication lines should always be arranged so used.

  • Page 46: Progressive System Ventilation

    4.15 Single-line system ventilation  Fill pump with lubricant.  Fill pump with lubricant. The rating plate of pump units KFG and KFGS  Remove main lines on unit.  Remove main lines (pressure relief valve as displays important speciications such as type  Allow pump to run until lubricant without...

  • Page 47: Notes On The Ce Marking

    4.17 Notes on the CE marking The CE marking is performed following the require- ments stated in the applied standards: ○ 2014/30/EU Electromagnetic Compatibility ○ 2011/65/EU (RoHS II) Directive on the restriction of the use of certain hazardous substances in electrical and electronic equipment Notes on the Low Voltage Directive The protective regulations of the low voltage directive...
  • Page 49 Page 49 KFG; KFGS; KFGL; KFGC for Operating instructions associated vehicle lubrication with assembly instructions according to EC Dir. 2006/42/EC for partly completed machinery...

  • Page 50: Safety Instructions

    Caused by the installation of non-original The safety instructions listed in Chapter 1, SKF components or SKF spare parts "Safety instructions," of the assembly instruc- Caused by inappropriate usage tions also apply without restrictions to these...

  • Page 51: Transport, Delivery, And Storage

    Page 51 3. Transport, delivery, and storage 3.1 Lubrication units General notes SKF Lubrication Systems Germany GmbH products are packaged in accordance with standard commercial practice according to the Ambient conditions: dry and dust-free The product(s) can be enveloped in plastic...

  • Page 52: Assembly

    Information/instructions about assembling the an integrated control unit. The pump ensures unit, and ill level monitoring. KFG (S) (L) (C) pump units beyond the scope of demand-based supply of lubricant to central- A short description of the individual assem- the assembly instructions are contained later ized lubrication systems with progressive feed- blies follows below.

  • Page 53: Lubricant Reservoir

    The output signal is confined to the following pump units without an integrated control unit. indications: The KFG pump is available in the versions with  Reservoir full grease reservoir and in reservoir capacities The lubricant reservoir is available in 2 kg, 6 kg,  Reservoir empty...

  • Page 54: Kfgs Pump Units

    The control unit can be used to set the pump voir capacities and voltage designs and with A piston detector is used to monitor the feed- run time either: the same grease follower plates as the KFG/  based on pump speed ing operation on progressive systems. KFGS series.

  • Page 55: Kfgc Pump Units

    Pump units of the KFGC series are pump units In addition to valve control, the outputs can This allows the causes of operational faults to from the KFG series with an integrated CAN also be configured as digital outputs for other be determined more easily.
  • Page 56 6. Functional description in progressive systems 6.1 Functional description for progressive 6.1.1 Pump element systems with a KFG pump unit A general progressive feeder system consists The pump element or elements meter out the Layout of the pump elements, Fig. 1...

  • Page 57: Kfgs Pump Units 54

    6. Functional description in progressive systems Page 57 6.1.2 Pressure regulating valve Example of progressive system with KFG pump unit, Fig. 3 A pressure regulating valve can be installed on the pump element on progressive systems to prevent excessive operating pressure in the lubrication system.

  • Page 58: Functional Description In

    Example of progressive system with KFS/KFGL pump unit, Fig. 4 KFGS or KFGL pump unit The general functional description for progres- sive systems with a KFG pump unit also applies for the design with KFGS and KFGL pump control. The control unit integrated into the pump...

  • Page 59: Functional Description In

    6. Functional description in progressive systems Page 59 Progressive systems with When CAN commands are used for control, the valves in a carefully coordinated sequence KFGC (CAN bus) pump unit valve opening must be ensured by selecting so that only one valve is opened at a time. The general functional description for progres- the appropriate contact and interval times or sive systems with a KFGS pump unit also...
  • Page 60 Page 60 7. Functional description in single-line systems 7. Functional description in single-line systems 7.1.1 Pump element KFG-Pump unit 7.1.3 Pressure regulating valve A general single-line system consists of a The pump element delivers the lubricant ac- A pressure regulating valve can be installed...
  • Page 61 7. Functional description in single-line systems Page 61 Example of single-line system with KFG pump unit, Fig. 7 Single-line system with KFG pump unit KFG unit Pump element with pressure relief valve with integrated pressure regulating valve Fill level switch...

  • Page 62: Functional Description: (Single-Line

    KFGL-Pump unit The general functional description for sin- The LC502 control unit integrated into the gle-line systems with a KFG pump unit also pump housing allows the following additional applies for the design with KFGL pump control. configuration, monitoring and connectivity options:  I nterval time and contact time can be ad-...
  • Page 63 7. Functional description in single-line systems Page 63 Example of single-line system with KFGL pump unit, Fig. 8 Legend to figure of KFGL single-line system Unit with pump element, LC 502 control unit Pump element with pressure relief valve with integrated pressure regulating valve Fill level switch Main line Single-line distributor...
  • Page 64 The general functional description for sin- ate a single-line system with up to four lubri- unit, a single-line system can be divided into gle-line systems with a KFG pump unit also cation zones. The system can be equipped with up to four individually controllable lubrication...

  • Page 65: General Commissioning

    Page 65 8. Commissioning 8. Commissioning General commissioning The reservoir unit described here functions Warning! automatically. The lubricant transport in the Different lubricants cannot be mixed, Before the product is commissioned, all elec- lubrication lines should, however, be subjected as mixing may result in damage and trical connections must be inspected.

  • Page 66: Kfgs Control Unit

    Page 66 9. KFGS control unit 9. KFGS control unit Display and control elements of Display and control elements of the KFGS control screen control screen Symbol Description Function Three-digit LED display Values and operating status The display and control unit is protected from water splashes and mechanical damage by a transparent plastic cover.

  • Page 67: Three-Digit Led Display

    9. KFGS control unit Page 67 9.1.1 Three-digit LED display Three-digit LED display The display is off in normal mode. It can be ac- Display Meaning Statement Control function tivated by briefly pressing one of the two = TIMER The control unit is functioning as Part of lubrication cycle;...
  • Page 68 Page 68 9. KFGS control unit Continuation of "Three-digit LED display" table Display Meaning Statement Control function Pressure Switch Pressure switch monitoring is The system pressure is mon- Three-digit LED display, Fig. 12 Pressure switch active. itored by the pressure switch (single-line systems) during the pump cycle The minimum fill level has been...

  • Page 69: Led Display

    9. KFGS control unit Page 69 9.1.2 LED display LED display LED lights up = display mode LED flashes = programming mode Operating voltage is present on pump unit Value for PAUSE can be changed. LED display, Fig. 13 and control unit, system is currently in operating status PAUSE Operating voltage is present on pump unit Value for CONTACT can be changed.

  • Page 70: 59 9.1.3 Pushbutton Operation

    Page 70 9. KFGS control unit 9.1.3 Pushbutton operation Pushbutton operation Function Pressing during PAUSE triggers an interim lubrication. Pushbutton, Fig.14 Fault notifications are acknowledged 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 mode, reduce displayed value by 1.

  • Page 71: Kfgs Display Mode

    9. KFGS control unit Page 71 KFGS display mode Display mode Display mode can be identified by the lit-up Step Display LED displays. The display does not flash. It is The current operating status is shown used to query the current settings and operat- Example: Pause Timer operation ing parameters.
  • Page 72 Page 72 9. KFGS control unit Continuation of "Display mode" table Step Display Monitoring switched off Monitoring via (On progressive (factory setting) Piston detector systems not admissible!) Display operating hours 10/11 Example: 1st part 2nd part of total value of total value Total value: 00533.8 h Write down.

  • Page 73: Kfgs Programming

    "Pump cycle time Timer operation" conirmed using the Press briefly "CONTACT" LED flashes key. (confirm new value) Pump cycle time 4.0 (factory setting) For the permissible setting range for KFG(S) 90-264 VAC -see Technical Data, Chapter 13 Press briefly (display in minutes)
  • Page 74 Page 74 9. KFGS control unit Continuation of "Change lubrication interval times" table Step Display Set new value Example: 3 min Press briefly (confirm new value) Changes are written to memory, the values are activated, and the display clears Press for more than 2 s...
  • Page 75 9. KFGS control unit Page 75 9.3.3 Conigure system monitoring Configure system monitoring Step Display System monitoring can be changed to activate Display flashes or deactivate the monitoring functions for (000 factory setting) Press for more than 2 s lubrication. Automatic display of first parameter: When system monitoring is active, you can se- "pause in timer operation"...

  • Page 76: Change Operating Modes

    Page 76 9. KFGS control unit 9.3.4 Change operating modes Change operating mode Step Display A change of operation mode means changing Display flashes to timer operation, counter operation or special (000 = factory setting) applications. Press for more than 2 s Automatic display of first parameter: "pause in timer operation"...

  • Page 77: Change Access Code

    Press briefly (confirm code) programmed if the code is lost or for- gotten. In this case, the pump unit must Display flashes be sent to the dealer or authorized SKF branch ofice. Press briefly (000 = factory setting) (confirm key) Press briefly...

  • Page 78: Programming Ranges

    PAUSE and PAUSE: Values in pulses CONTACT. CONTACT: Values in minutes 1) For the permissible setting range for KFG(S) 90-264 VAC, see Technical Data, Chapter 13. PAUSE: Values in hours A switch opens and closes based on machine CONTACT: Values in minutes movements, revolutions, etc.

  • Page 79: No System Monitoring

    9. KFGS control unit Page 79 9.4.3 No system monitoring Fill level monitoring 9.5.1 Monitoring via piston detector If ill level monitoring is installed, it is In this operating mode, the lubrication cycle Only possible for centralized lubrication is controlled solely by the pre-set values for always active. systems with progressive feeders.
  • Page 80 Page 80 9. KFGS control unit Monitoring via piston detector, Fig. 17 Progressive system with piston detector 1 KFGS unit 4 Fault indicator light Piston detector 2 Pump element with 5 Fill level switch Secondary feeder pressure regulating valve 6 Main lines Lubrication points 3 Power supply 7 Master feeder...

  • Page 81: Kfgl Control Unit

    10. KFGL control unit Page 81 10. KFGL control unit 10.1 Display and control elements of control screen Display and control elements of control screen The display and control unit is protected from water splashes and mechanical damage by a Symbol Description Function...
  • Page 82 Page 82 10. KFGL control unit Display and control elements of control screen Symbol Description Function Operator keys Operator keys  for menu selection (navigation)  for editing numerical values Operator keys Operator keys for menu selection (navigation) (arrow key up/down/left) Go to the selected menu based on direction of arrow Operator keys for editing numerical values (arrow key up/down)

  • Page 83: Display And Control Menu

    The first menu level shows language selection. The Service menu selection is pass- The language that is currently selected flashes. word-protected and can only be Upon confirmation, the main menu will be dis- accessed by SKF employees. played in the selected language.

  • Page 84: Info - Information Mode

    - keys. Main menu items Info menu KGFL, Fig. 21 Display Description Display device-speciic data such as serial number or irmware Info Info Conig Parameter settings Config.uration Status Display current status of control unit Status Service menu Service Menu level only enabled for SKF service personnel...
  • Page 85 10. KFGL control unit Page 85 Information mode Step Display Description Entry mask/language selection The German version is active by default (flashing). English Press the “up” arrow key to change to the English version. Press the ENTER key German Main menu Info Press the ENTER key to go to the Info menu.
  • Page 86 Page 86 10. KFGL control unit 10.2.3 Conig. - Coniguration mode Configuration menu, table 1 of 2 Configuration mode is started by selecting Step Display Description <Config.> in the main menu and pressing the Entry mask/language selection ENTER key. First you need to specify whether you want to edit the configuration data or view The German version is active by default (flashing).
  • Page 87 10. KFGL control unit Page 87 Configuration menu, table 2 of 2 Step Display Description Edit Display Press the ENTER key to go to the password prompt menu. Press the ENTER key Edit Password menu The following request for a password prevents changes being made by unauthorized persons. Password Press <...

  • Page 88: Programming A Kfgl Pump Unit

    Page 88 10. KFGL control unit 10.3 Programming a KFGL pump unit Detailed, separate operating instructions for the IC502 control unit are supplied together with these assembly instructions. Chapter 5 of these operating instructions lists the adjustment options available to the customer.

  • Page 89: Kfgc Control Unit

    11. KFGC control unit Page 89 11. KFGC control unit 11.1 KFGC series (CAN bus) Display and control elements of the KFGC control screen The display and control screen is protected Symbol LED color Description Function from water splashes and mechanical dam- Green POWER LED Lights up when operating voltage pres-...
  • Page 90 Page 90 11. KFGC control unit Display KFGL, Fig. 23 Continuation of "Display and control elements of the KFGC control screen" table Symbol Description Function IrDA interface Infrared service interface  Read stored status data and fault notifications  Configure the control unit via PC ...

  • Page 91: Shutdown/Disposing

    To recommission the product, follow the in- The product can also be returned to SKF structions in the Chapter "Assembly." Lubrication Systems Germany GmbH for dis- posal, in which case the customer is responsi- ble for reimbursing the costs incurred.

  • Page 92: Maintenance And Service

    The product must incorrect or contaminated lubricant is acciden- therefore be depressurized before tally filled into the product. If this occurs, starting assembly, maintenance or re- please contact the Service department of SKF pair work, or any system modiications Lubrication Systems for assistance. or system repairs.

  • Page 93: General Information

     I nspect electrical connections in case of All work beyond this scope must be malfunction notiications performed by authorized SKF Service  R eplace defective fuses with new fuses of establishments. the same performance and characteristics...
  • Page 94 Observe the instructions contained in these operating instructions. If necessary, please contact an SKF service office. KFGS; KFGL; KFGC Check of basic function of To inspect the basic functions, trigger an interim lubrica-...

  • Page 95: Operational And Pump Faults

    14. Operational and pump faults Page 95 14. Operational and pump faults 14.1 Operational malfunctions 14.1.2 Malfunctions on pump units 14.1.1 General information Pump malfunctions Fault Possible cause Rectification The operator/operating personnel must perform  Mechanical damage, e.g., visual fill level control of the lubricant reservoir Pump Agitator in •...
  • Page 96 Page 96 14. Operational and pump faults Pump malfunctions Fault Possible cause Rectification  Electrical control has failed. Pump does not • Check fuse. function when the  Pump drive/motor is defective. key is pressed, • Replace pump. although all electrical ...

  • Page 97: Malfunctions On Kfgs Pump Units

    14. Operational and pump faults Page 97 14.2.2 Delete fault notiication 14.2 Malfunctions on KFGS pump unit 14.2.1 Display faults  A ll fault notiications can be acknowl-  S tart the display mode with one of the All fault notifications are displayed by the as a centralized fault notification. keys edged and deleted using the key.

  • Page 98: Fault Types

    Page 98 14. Operational and pump faults 14.2.3 Fault types Depending on the severity of the fault, the control unit issues either a warning or a mal- function notiication (see following table). Fault types Fault type Definition Display Example of fault Response by control unit ...

  • Page 99: Recording Fault Times

    14. Operational and pump faults Page 99 14.2.4 Recording fault times 14.2.5 Malfunctions on KFGS pump unit with a progressive feeder system Fault-state counter Block operation A total of three lubrication cycles are The amount of time that passes from issuance Block operation is the reaction of the control performed with query to the piston of a failure notiication to its acknowledgment...

  • Page 100: Malfunctions On Kfgl Pump Unit

    Page 100 14. Operational and pump faults 14.3 Malfunctions on KFGL pump unit 14.3.1 Display faults 14.3.3 Fault types 14.3.4 Fault notiications All fault notifications are displayed by the Warning! Determine and remedy the cause of faults before deleting fault notiications. Detailed, separate operating instructions for Key to LED display: The user is liable for damages resulting the IC502 control unit are supplied together...

  • Page 101: Malfunctions On Kfgc Pump Unit

    14. Operational and pump faults Page 101 14.3 Malfunctions on KFGC pump unit 14.3.1 Faults detected by control unit 14.3.2 Fault types All fault notifications are displayed by the The comprehensive monitoring functions of the LC-CAN 5000 control unit allow faults in 14.3.3 Read faults the operational process to be detected, regis-...

  • Page 102: Technical Data

    15. Technical data Protective measures that must be taken for Continuation of "Technical Data" table operation according to the intended use in machinery: Data universally applicable to KFG, KFGS; KFGL; KFGC KFG; KFGS; KFGL, KFGC... 24 VDC: Description Key data/Display ...
  • Page 103 IP56 Operating mode/ON-time according to VDE0530/ DIN 41756 continuous operation Data universally applicable to KFG, KFGS; KFGL; KFGC 300 bar with spring return pump elements Max. back pressure 350 bar with spring return pump elements Max. Number of outlets (if less than 3 outlets are required, close unneeded outlets with screw plugs) KFG1.U1 = 2.5...
  • Page 104 Page 104 16. Technical data Continuation of "Technical Data" table KFGC data Description Key data Switching outputs All types Type Solid-state output, short-circuit-proof and overload-proof Max. current-carrying capacity • with simultaneous operation of 4 outputs: 1.0 A • with simultaneous operation of 2 outputs: 1.25 A •...

  • Page 105: Accessories

    16. Accessories Page 105 16. Accessories Accessories Description Data Order No. M12x1 connector, 4-pin with 5 m cable, 4x 0.25 mm , protection class IP 67 (mounted) 179-990-719 Double-pin plug (T-connector) Double-pin plug (two-way distributor) (for connecting to the M12x1 plug on the pump 179-990-700 with 2x M12x1 outputs for piston detector and separate indicator lamp) M12x1 socket...
  • Page 106 Page 106 17. Accessories The operating instructions/functional description of the corresponding control unit must be observed! External control units Application Type designation Features Order number Piston distributor for EXZT2A02-E Pulse generator/counter with adjustable interval time, interval time extension, monitor- single-line systems ing of pressure build-up and reduction, and fill level monitoring Piston distributor for EXZT2A03-E...
  • Page 107 17. Accessories Page 107 External control units Application Type designation Features Order number Progressive systems IGZ51-20-E Pulse generator/counter with selectable intermittent or continuous pump operation, with adjustable stroke rate, selectable interval time and monitoring time, and monitoring of fill level and pump cycle time Progressive systems IGZ51-20-S2-E Same as IGT51-20, but with non-volatile memory in case of power failure...
  • Page 108 If assembly/operating instructions are supplied together with the products, they must be read and followed. Not all lubricants can be fed using centralized lubrication systems. SKF can, on request, inspect the feedability of the lubricant selected by the user in centralized lubrication systems. Lubrication systems...

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