SKF KFGL Assembly Instructions Manual
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SKF KFGL Assembly Instructions Manual

For industrial applications. kfg series
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KFG; KFGS; KFGL; KFGC (CAN bus)
for industrial applications
ax
in
Use hard grease NLGI-2 only !
KFG
Version 03
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 industrial applications Use hard grease NLGI-2 only ! KFGS KFGL KFGL-MonoFlex KFGC Version 03...
  • Page 2 Page 2 Notes Service Masthead © SKF Lubrication Systems Germany GmbH If you have technical questions, please contact These assembly instructions with associated This documentation is protected by copyright. the following addresses: operating instructions according to EC Machinery SKF Lubrication Systems Germany GmbH re-...
  • Page 3 4.6.3.1 KFGL MonoFlex single-line Intended use 4.3.1 Pump element designs lubrication systems Authorized personnel 4.3.2 Pump elements with 4.6.3.2 KFGL ProFlex for progressive Electric shock hazard spring-return pistons centralized lubrication systems System pressure hazard 4.3.3 Assembly of a pump element 4.6.4...
  • Page 4 9.5.1 Monitoring via piston detector 5.2.3 Fill level monitoring 7.3.1 Systems with 3/2 directional solenoid valves 5.2.4 KFGS and KFGL control units 7.3.2 Multiple lubrication zones KFG pump units KFGS pump units KFGL pump units 8. Commissioning KFGC (CAN bus)
  • Page 5 Malfunctions on KFGS pump unit 10.2.2 Info - Information mode 14.2.1 Display faults 10.2.3 Config. - Configuration mode 14.2.2 Delete fault notification 10.3 Programming a KFGL pump unit 14.2.3 Fault types 14.2.4 Recording fault times 11. KFGC control unit 14.2.5 Malfunctions on KFGS pump unit 11.1...

  • Page 6: Conformity And Ec Declaration Of Incorporation

    When used in conformity with their intended (a) This declaration certifies compliance with machinery to form a machine. Within the use, the products supplied by SKF Lubrication the aforementioned Directives, but does not scope of application of the EC Directive, Systems Germany GmbH do not reach the limit constitute a guarantee of characteristics.

  • Page 7: Explanation Of Symbols And Signs

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

  • Page 8: Documentation Overview

    Page 8 Assembly instructions Documentation overview 1. Safety instructions Description/ The operator of the described product In addition to the assembly instructions, Document number must ensure that the assembly inst- general statutory regulations and other ructions are read and understood by regulations for accident prevention LC502 control unit for all persons tasked with the assembly,...

  • Page 9: Authorized Personnel

    Assembly instructions Page 9 Intended use Authorized personnel Pump units of SKF's KFG, KFGS, KFGL and Unless specially indicated otherwise, products Only qualified technical personnel may install, from SKF Lubrication Systems Germany GmbH 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 trai- on the unit if the protective earth during operation.

  • Page 11: Explosion Protection Information

    Only the pump models tested andap- install adequate overload protection for choice of the lubricant to be delivered that proved by SKF Lubrication Systems the power consumption of the motor. no chemical reactions capable of serving Germany GmbH in accordance with...

  • Page 12: Lubricants 2.1 General Information

    EC Directive 67/548/EEC, Article 2, Para. 2, the lubricants are critically important in these system in cooperation with the lubricant may only be filled into SKF centralized lubrica- considerations. supplier. tion systems and components and delivered...

  • Page 13: Approved Lubricants

    You can request an overview of the lubricant order to prevent accidental mixing of tests offered by SKF Lubrication Systems lubricants. Germany GmbH from the company's Service The product described here can be operated department.

  • Page 14: Lubricants And The Environment

    Page 14 Assembly instructions Lubricants and the environment Lubricant hazards Warning! Danger! Lubricants can contaminate soil and Centralized lubrication systems must al- bodies of water. Lubricants must be ways be free of leaks. Leaking lubricant properly used and disposed of. Observe is hazardous due to the risk of slipping the local regulations and laws regarding and injury.

  • Page 15: 3. Overview

    7 Electrical connection 4.5-4.5.3 8 Control port assignments 4.6-4.7.3 9 KFGS control unit OI Chapter 9 Use hard grease NLGI-2 only ! 10 KFGL control unit OI Chapter 10 11 KFGC control unit OI Chapter 11 KFGS KFGL KFGL-MonoFlex KFGC...

  • Page 16: Assembly 4.1 General Information

    The unit mounting position is vertical. a single unit of the KFG, KFGS or KFGL series to operate up to three independent zones. Any assembly holes must be made according The product must not be installed within The KFGC series is capable of operating up to to the diagram on the following page.

  • Page 17: Minimum Clearance Height For Installation

    Assembly instructions Page 17 4.2.1 Minimum clearance height for installation Warning! Warning! The minimum clearance height for installation Do not tilt or drop the KFG (S) (L) (C) depends on the reservoir design. On the pump units' electrical connec- tions, ensure that appropriate measures grease lubrication pump unit! prevent interference between signals To ensure enough space for maintenance work...

  • 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] Ø 9,0 10 kg 15 kg 342.5 20 kg 432.5 Use hard grease NLGI-2 only !

  • Page 19: Without Control Unit

    Assembly instructions Page 19 4.2.3 Mounting dimensions, 24 V DC 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 15 kg / 20 kg...
  • Page 20 Page 20 Assembly instructions 4.2.4 Mounting dimensions, 24 V DC and 90 to 264 V AC design, with control unit 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: Kfg (S) (L) (C) Pump Element Series

    (DIN 7603-A20x24-Al) can also three pump elements. be fitted if desired. Alternatively the screw plug Depending on the pump unit's application can be ordered from SKF under order number (ProFlex/MonoFlex) and configuration (KFG/ KFG 1.128. KFGS/KFGL/KFGC), it is possible to connect...

  • 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]...

  • 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 4.3.5 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: Pressure Regulating Valve

    Assembly instructions Page 25 • Section C Carefully pull the piston (6) out of Assembly, positively driven pump element, Fig. 9 the new pump element (1) Section A • Coat the bore of the pump element lightly with grease • Insert the piston in the bore of the pump Section C element, leaving as much of the piston as possible protruding from the bore...
  • Page 26 Page 26 Assembly instructions 4.3.6 Pressure regulating valve Pressure regulating valve Pressure regulating valve, Fig. 10 A pressure regulating valve (1) protects the Pressure regulating valve without entire lubrication system against excessive lubricant nipple system pressure. It is mounted directly on the Tube Ø...

  • Page 27: Information On Lubricant Filling

    Assembly instructions Page 27 4.4 Information on lubricant filling Pressure regulating valve Pressure regulating valve with Only fill using clean lubricant and an Filling, Fig. 12 T connector output appropriate filling 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 head nipple (1) the unit can also be fitted with pump unit can optionally be filled via one of a filler socket (part No. 995-000-705) (2)for the lubricant outlets using a filling cylinder (1). filling by means of a filler pump. A correspon- This is done by removing the screw plug ding coupling socket (part No.

  • Page 29: Electrical Power Supply

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

  • Page 30: Power Supply 24 Vdc

    Page 30 Assembly instructions KFG...DC KFG...DC 4.5.2 Power supply 24 VDC 4.5.3 Power supply 90-264 VAC Power supply 24 VDC, Fig. 16 Power supply 90-264 VAC, Fig. 17 Cable socket per Cable socket per DIN EN 175301-803 DIN EN 175301-803 (Fahrzeug) (Fahrzeug) (Industrie)

  • Page 31: Control Port Assignments

    Assembly instructions Page 31 Control port assignments 4.6.2 KFGS series 4.6.1 KFG series With integrated IG502 control unit You can find technical data and the 4.6.1.2 External control unit The KFGS pump unit is available in the order number of the M12x1circular voltage designs 24 VDC, 90-264 VAC and connector (mating part for circular plug 120-370 VDC.

  • Page 32: Timer Mode

    Page 32 Assembly instructions 4.6.2.1 Timer mode Connectivity Timer operation without system monitoring Timer mode Positioning of socket, Fig. 18 Timer operation without system monitoring, Fig. 19 In timer mode, the interval time is determined 24 VDC by a time value. It is configured by entering a time value in hours.
  • Page 33 Assembly instructions Page 33 Connectivity Timer operation with Connectivity: Timer operation with system monitoring, fill level control, system monitoring piston detector and indicator light. Timer operation with system monitoring, Fig. 20 T-connector, Fig. 21 Connection for fault notification SL2 24 VDC + PIN Code Assignment Fault indicator light ( - ) Fault indicator light ( + ) Connection for piston detector CS PIN Code...
  • Page 34 Page 34 Assembly instructions 4.6.2.2 Control using machine pulses (Counter mode) Control using machine pulses Positioning of socket, Fig. 22 (load-dependent lubrication) The duration of the interval time is determined by a pulse generator that sends pulses to the control unit based on how long the machine has been running.
  • Page 35 Assembly instructions Page 35 Connectivity Counter operation without Connectivity Counter operation with system monitoring system monitoring Counter operation without Connector pin assignment without Counter operation with system monitoring, Fig. 23 system monitoring system monitoring, Fig. 24 Code Assignment KFGS... KFGS... Not assigned MK/DK Machine contact/...

  • Page 36: Kfgl Series

    4.6.3 KFGL series 4.6.3.1 KFGL MonoFlex single-line lubrication systems With integrated LC502 control unit KFGL pump unit, MonoFlex programming, 24 VDC, Fig. 25 The KFGL pump unit is available in the voltage designs 24 VDC, 90-264 VAC and 120-370 VDC.
  • Page 37 Assembly instructions Page 37 KFGL pump unit, MonoFlex programming, 230 VAC, Fig. 26 Input 1 (In 1) Pin 1: Pressure switch 1 (+) Pin 4: Pressure switch 1 (-) Output 1 (Out 1) Pin 2: Valve (+) Pin 3: Valve (-)

  • Page 38: Kfgl Proflex For Progressive Centralized Lubrication Systems

    Page 38 Assembly instructions 4.6.3.2 KFGL ProFlex for progressive centralized lubrication systems KFGL pump unit, ProFlex programming, 24 VDC, Fig. 27 Betriebsspannung operating voltage 24VDC Output 1 (Out 1) Standard model = Disabled system with two main lines Pin 3: Valve (-)
  • Page 39 Assembly instructions Page 39 KFGL pump unit, ProFlex programming, 230 VAC, Fig. 28 Input 1 (In 1) Pin 1: Cycle switch 1 (+) Pin 4: Cycle switch 1 (-) Output 1 (Out 1) Pin 2: not programmed (-) Sensor/actuator adapter...

  • Page 40: Switch Or Cycle Switch And Valve

    See connection dia- Valve Out 1/Out 2 Valve ( + ) gram for KFGL pump unit, MonoFlex program- ming, 230 VAC, Fig. 26 or KFGL pump unit, ProFlex programming, 230 VAC, Fig. 28 Piston detector (CS) PIN Code Assignment...

  • Page 41: Kfgc Series (Can Bus)

    Assembly instructions Page 41 4.6.5 KFGC series (CAN bus) 4.6.5.1 KFGC ProFlex and KFGC MonoFlex The KFGC pump unit is available in the voltage KFGC pump unit, ProFlex and KFGC MonoFlex, 24 VDC, Fig. 30 design 24 VDC. There is also a 3-pin Deutsch connector on the underside for the CAN bus connection.

  • Page 42: Connection Of 5/4 Directional Control Valve

    Page 42 Assembly instructions 4.6.5.2 KFGC ProFlex - rotary , for connection of 5/4 directional control valve KFGC pump unit, ProFlex, 24 VDC, with 5/4 directional control valve, Fig.31 Input 1 (In 1) Pin 1: CS 1 (+) A = CAN-H Pin 4: CS 1 (-) B = CAN-B Socket (female connectors)

  • Page 43: Pressure Relief Valve With Integrated Pressure Regulating Valve

    Assembly instructions Page 43 4.6.6 Pressure relief valve with integrated pressure regulating valve (for single-line systems with VR distributors) Technical data Pressure relief valve/pressure regulating valve, Fig. 32 Pressure relief valve 24 VDC Input voltage ... 24 VDC Hydraulic Rated output .

  • Page 44: Fill Level Monitoring

    Page 44 Assembly instructions Fill level monitoring Fill level monitoring W1, Fig. 33 Three different fill level switches can be fitted as standard on the KFG pump unit for the pur- pose of indicating the “Minimum” lubricant fill level.  Order code 1 (formerly W1 control) for greases of NLGI >...
  • Page 45 Assembly instructions Page 45 4.7.1 Fill level monitoring, order code 1 (W1) max. 24 VDC, for greases of NLGI Grade ≥ 2 Connection W1, Fig. 34 Functional description Technical data Fill level monitoring The fill level switch W1 is designed as a rocker Function .
  • Page 46 Page 46 Assembly instructions 4.7.2 Fill level monitoring, order code 2 (W1G) with dry contact, signal smoothing, max. 24 VDC, for greases of NLGI Grade ≥ 2 Fill level monitoring W1G, Fig. 35 The following functions are integrated for the Technical data KFG pump unit with signal smoothing: Fill level monitoring...
  • Page 47 Assembly instructions Page 47 4.7.3 Fill level monitoring, order code 3 (W2) Warning! For greases of class NLGI ≤ 1 only Technical data W2 with cable, Fig. 36 W2 with cable box, Fig. 37 Fill level monitoring Function ..Switch opens at min. + fill lvl fault notification and upon wire breakage.

  • Page 48: Pump Unit Fill Level Control Visual

    DIN 2353can be Lubrication lines should always be arranged so For KFGL and KFGC, see Chapter 14, Fault used. If using fittings from other manufactur- that air pockets cannot form anywhere. Avoid notifications.

  • Page 49: Progressive System Ventilation

     Mount screw plug or pressure switch.  Vent lubrication lines and lubrication points Type designation SKF Lubrication Systems Germany GmbH and inspect for proper function. Power supply Barcode Made in Germany...
  • Page 51 Page 51 KFG; KFGS; KFGL; KFGC for Operating instructions associated industrial applications with assembly instructions according to EC Dir. 2006/42/EC for partly completed machinery...

  • Page 52: 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 instructions Caused by inappropriate usage also apply without restrictions to these opera- Resulting from improper assembly, ting instructions.
  • Page 53 Page 53 3. Transport, delivery, and storage Lubrication units General notes SKF Lubrication Systems Germany GmbH pro- ducts are packaged in accordance with stan- Ambient conditions: dry and dust-free The product(s) can be enveloped in plastic dard commercial practice according to the surroundings, storage in well ventilated film to provide low-dust storage.

  • Page 54: Lubricants

    5.1 General information 5.2 Design The assembly procedure for KFG pump units is Pump units of the KFG, KFGS, KFGL and KFGC Pump units of the KFG, KFGS, KFGL and KFGC described in detail in the assembly instructions series are electrically driven reservoir...
  • Page 55 Fill up to three lubrication zones to be lubricated and control screen is mounted on the front side of the KFGS or KFGL design, while the level control W1 (order code 1) and fill level independently. Sectional lubrication is available KFGC design has a display attached.

  • Page 56: Assembly

    (contact) can be entered easy to operate The KFGL pump is available in the same reser- through the control unit. The control unit can be used to set the pump voir capacities and voltage designs and with...

  • Page 57: Design And Function

    (minimum), monitoring the signal lines on at- and monitor up to four independent zones and tached components for line breakage, and mo- You can find further descriptions of the SKF- to supply them from a single pump unit. nitoring the switching outputs for short...
  • Page 58 Page 58 6. Functional description in progressive systems 6. Functional description in progressive systems 6.1 Functional description for progressive systems with a KFG pump unit A general progressive feeder system consists their individual volume requirements. From Layout of the pump elements, Fig. 1 of the following components: there, the lubricant flows to the lubrication points.
  • Page 59 6. Functional description in progressive systems Page 59 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 60: Pump Housing

    Page 60 6. Functional description in progressive systems Progressive system with a KFGS or Example of progressive system with KFS/KFGL pump unit, Fig. 4 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.
  • Page 61 6. Functional description in progressive systems Page 61 Progressive systems with KFGC (CAN bus) pump unit The general functional description for progres- When CAN commands are used for control, in the external lubrication program to switch valve opening must be ensured by selecting sive systems with a KFGS pump unit also the valves in a carefully coordinated sequence applies for the design with CAN bus pump...

  • Page 62: Lubricant Reservoir

    Page 62 7. Functional description in single-line systems 7. Functional description in single-line systems KFG-Pump unit 7.1.1 Pump element 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 cording to the capacity of the connected single- single-line systems to prevent excessive ope- pump unit with pump element and pressure...

  • Page 63: Kfg Pump Units

    7. Functional description in single-line systems Page 63 Example of single-line system with KFG pump unit, Fig. 7 Single-line system with KFG pump unit 1 KFG unit 2 Pump element with pressure relief valve with integrated pressure regulating valve 3 Fill level switch 4 Main line 5 Single-line distributor 6 Pressure gauge for pressure build-up...
  • Page 64 The LC502 control unit integrated into the line systems with a KFG pump unit also applies pump housing allows the following additional for the design with KFGL pump control. configuration, monitoring and connectivity options:  I nterval time and contact time can be...

  • Page 65: Kfgl Pump Units

    7. Functional description in single-line systems Page 65 Example of single-line system with KFGL pump unit, Fig. 8 Legend to figure of KFGL single-line system 1 Unit with pump element, LC 502 control unit 2 Pump element with pressure relief valve...

  • Page 66: Functional Description In

    Page 66 7. Functional description in single-line systems 7.3.2 Multiple lubrication zones Functional description in single-line 7.3.1 Systems with 3/2 directional systems with a KFGC (CAN-Bus) solenoid valves pump unit Directional solenoid valves can be used to Using the integrated LC-CAN 5000 control The general functional description for single- create a single-line system with up to four lub- unit, a single-line system can be divided into...
  • Page 67 8. Commissioning Page 67 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 as mixing may result in damage and lubrication lines should, however, be subjected electrical connections must be inspected.

  • Page 68: Progressive Systems

    Page 68 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 69 9. KFGS control unit Page 69 9.1.1 Three-digit LED display Three-digit LED display Display Meaning Statement Control function The display is off in normal mode. It can be ac- = TIMER The control unit is functioning as Part of lubrication cycle; tivated by briefly pressing one of the two PA = PAUSE a timer and is currently in PAUSE...
  • Page 70 Page 70 9. KFGS control unit Continuation of "Three-digit LED display" table Display Meaning Statement Control function Pressure switch monitoring is The system pressure is moni- Pressure Switch Three-digit LED display, Fig. 12 Pressure switch active. tored by the pressure switch (single-line systems) during the pump cycle Low Level...
  • Page 71 9. KFGS control unit Page 71 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 72 Page 72 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 73 9. KFGS control unit Page 73 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 operating Example: Pause Timer operation parameters.
  • Page 74 Page 74 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 75 9. KFGS control unit Page 75 KFGS programming The working/interval times can be reprogram- Change lubrication interval times med to adapt the lubrication intervals and Step Display the resulting lubricant quantities to specific Display flashes requirements. (000 factory setting) Press for more than 2 s Automatic display of first parameter: 9.3.1 Start programming mode "pause in timer operation"...
  • Page 76 Page 76 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 77 9. KFGS control unit Page 77 Configure system monitoring 9.3.3 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 "pause in timer operation"...
  • Page 78 Page 78 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 79 (321 = factory default setting) programmed if the code is lost or for- Press briefly (confirm code) gotten. In this case, the pump unit must be sent to the dealer or authorized SKF Display flashes branch office. Press briefly (000 = factory setting)
  • Page 80 Page 80 9. KFGS control unit 9.3.6 Programming ranges KFGS operating modes 9.4.2 Counter operation 9.4.1 Timer operation The interval depends on the number of pulses; Programming ranges the pump cycle time is time-dependent. Function Programming range The interval and pump cycle are time- An external pulse generator must be attached Interval time 0.1 h to 99.9 h...
  • Page 81 9. KFGS control unit Page 81 9.4.3 No system monitoring Fill level monitoring 9.5.1 Monitoring via piston detector In this operating mode, the lubrication cycle If fill level monitoring is installed, it is Only possible for centralized lub- is controlled solely by the pre-set values for rication systems with progressive always active.

  • Page 82: Pump Element

    Page 82 9. KFGS control unit Monitoring via piston detector, Fig. 17 Progressive system with piston detector 1 KFGS unit Fault indicator light Piston detector 2 Pump element with pressure Fill level switch Secondary feeder regulating valve Main lines Lubrication points 3 Power supply Master feeder...
  • Page 83 10. KFGL control unit Page 83 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...
  • Page 84 Page 84 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)
  • Page 85 10. KFGL control unit Page 85 10.2 Display and control menu 10.2.1 Main menu The control unit's display has three rows of eight Control screen KGFL, Fig. 19 Main menu KGFL, Fig. 20 characters each. Only three options are shown in menu windows containing more than three available choices.
  • Page 86 Main menu items Info menu KGFL, Fig. 21 Display Description Display device-specific data such as serial number or firmware Info Info Parameter settings Config.uration Config Status Display current status of control unit Status Service menu Service Menu level only enabled for SKF service personnel...
  • Page 87 10. KFGL control unit Page 87 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 88 Page 88 10. KFGL control unit 10.2.3 Config. - Configuration 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 89 10. KFGL control unit Page 89 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.

  • Page 90: Pump Unit

    Chapter 5 of these operating instructions lists the adjustment options available to the customer. Document no. 951-180-004-EN For the programming of a KFGL pump unit in MonoFlex design (single-line centralized lubri- cation system) Document no. 951-180-005-EN For the programming of a KFGL pump unit in...
  • Page 91 White BUS LED Lights up when communication with the CAN network has been successfully established. Display KFGL, Fig. 22 Yellow CS/MC LED Lights up briefly when the control unit detects a signal edge at an input from a piston detector (CS), pressure switch (PS) or from the machine contact (MC).
  • Page 92 Page 92 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 93 To recommission the product, follow the The product can also be returned to SKF instructions in the Chapter "Assembly." Lubrication Systems Germany GmbH for dis- posal, in which case the customer is respon- sible for reimbursing the costs incurred.

  • Page 94: Maintenance And Service

    The product must incorrect or contaminated lubricant is acciden- therefore be depressurized before st- tally filled into the product. If this occurs, ple- arting assembly, maintenance or repair ase contact the Service department of SKF work, or any system modifications or Lubrication Systems for assistance. system repairs.
  • Page 95 All work beyond this scope must be  I nspect electrical connections in case of performed by authorized SKF Service malfunction notifications establishments.  R eplace defective fuses with new fuses of...

  • Page 96: Commissioning

    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 97 14. Operational and pump faults Page 97 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 per- form visual fill level control of the lubricant re- Pump Agitator in •...
  • Page 98 Page 98 14. Operational and pump faults Pump malfunctions Fault Possible cause Rectification Pump does not • Check fuse.  Electrical control has failed. function when the key is pressed, • Replace pump.  Pump drive/motor is defective. although all electrical connections are ok.
  • Page 99 14. Operational and pump faults Page 99 14.2 Malfunctions on KFGS pump unit 14.2.1 Display faults 14.2.2 Delete fault notification  All fault notifications are displayed by the  S tart the display mode with one of the A ll fault notifications can be acknow- as a centralized fault notification. keys ledged and deleted using the key.
  • Page 100 Page 100 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 notification (see following table). Fault types Fault type Definition Display Example of fault Response by control unit Malfunction A fault has occurred that affects -LED lights up Insufficient number of piston...
  • Page 101 14. Operational and pump faults Page 101 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 Block operation is the reaction of the control The amount of time that passes from issuance performed with query to the piston of a failure notification to its acknowledgment...

  • Page 102: Main Menu

    Page 102 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 notifications All fault notifications are displayed by the Warning! Determine and remedy the cause of faults before deleting fault notifications. Detailed, separate operating instructions for...

  • Page 103: Operational And Pump Faults

    14. Operational and pump faults Page 103 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, regi-...

  • Page 104: Technical Data

    15. Technical data 15. Technical data Protective measures that must be taken for Technical data operation according to the intended use in Data universally applicable to KFG, KFGS; KFGL; KFGC machinery: KFG; KFGS; KFGL, KFGC... 24 VDC: Description Key data/Display Conditions for electrical connections "Functional Extra Low Voltage",...
  • Page 105 • 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, KFGS; KFGL; KFGC 300 bar with spring return pump elements Max. back pressure 350 bar with spring return pump elements Max.
  • Page 106 Page 106 15. 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 107 16. Accessories Page 107 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 108 Page 108 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, monito- single-line systems ring of pressure build-up and reduction, and fill level monitoring EXZT2A03-E Piston distributor for...
  • Page 109 17. Accessories Page 109 External control units Application Type designation Features Order number IGZ51-20-E Progressive systems 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 110 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.

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