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MicroDosage System (MDS)
for continuous lubrication of high-speed spindles
with minimum quantities of oil from 0.5 to 5 mm
MDR lubricant reservoir
MDR
MDU
Machine tool control unit
Version 04
Assembly instructions
for partly completed machinery with associated operating instructions
/min
3
MDU micro-metering unit
Tool spindle
acc. to EC Dir. 2006/42/EC
EN
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Summary of Contents for SKF MicroDosage System
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Page 1: Microdosage System (Mds)
MicroDosage System (MDS) Assembly instructions acc. to EC Dir. 2006/42/EC for partly completed machinery with associated operating instructions for continuous lubrication of high-speed spindles with minimum quantities of oil from 0.5 to 5 mm /min MDR lubricant reservoir MDU micro-metering unit... - Page 2 Page 2...
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Page 3: Service
Notes Page 3 Service Masthead © SKF Lubrication Systems Germany GmbH If you have technical questions, please contact This documentation is protected by copyright. These assembly instructions with associated the following addresses: operating instructions according to EC SKF Lubrication Systems Germany GmbH re-... -
Page 4: Table Of Contents
Page 4 Table of contents Table of contents Assembly instructions MicroDosage System (MDS) 3. Overview 4.4.2 Assembly drawing with minimum Service SKF microdosage system installation dimensions Information concerning EC Declaration of MDU micro-metering unit 4.4.3 Capillary line connection Conformity and EC Declaration of Incorporation MDR lubricant reservoir designs 4.4.4 Arrangement of capillary lines... - Page 5 Installation and use on spindles Temporary shutdown 4.2.1 Spindle design Permanent shutdown 4.2.2 Lubricant quantity 4.2.3 Filling lubricant ducts in the spindle 8. Maintenance and service General information 5. Design and function Maintenance and repair General information42 Principle of the SKF microdosage system 43...
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Page 6: Information Concerning Ec Declaration Of Conformity And Ec Declaration Of Incorporation
When used in conformity with their intended Low Voltage Devices 2014/35/EU other machinery to form a machine. Within use, the products supplied by SKF Lubrication RoHS II Directive 2011/65/EU the scope of the EC Directive, commission- Systems Germany GmbH do not reach the... -
Page 7: Explanation Of Symbols And Signs
Explanation of symbols Page 7 Explanation of symbols and signs You will find these symbols, which warn of Instructions placed directly on the product, You are responsible! specific dangers to persons, material assets, or such as: the environment, next to all safety instructions Rotation arrows Please read the assembly and operating in- in these assembly and operating instructions. -
Page 8: Safety Instructions
The SKF microdosage system MDS, together Therefore the product may only be used in with the products MDU micro-metering unit... -
Page 9: Authorized Personnel
Unless specially indicated otherwise, products Assembly, maintenance, and repair work may only be performed on pro- from SKF Lubrication Systems Germany GmbH The definition of qualified personnel and the are not approved for use in potentially explosive prohibition against employing non-qualified ducts that have been de-energized by areas as defined in the ATEX Directive 94/9/EC. -
Page 10: System Pressure Hazard
Compressed air hazard improperly or not performed at all Conductors or component connections o Use of non-original SKF components or within the device must not be touched The lubricant reservoir is pressurized with spare parts under any circumstances. -
Page 11: Existing Residual Risks
Assembly instructions Page 11 Existing residual risks (residual risk assessment) Residual risk Remedy Life cycle: Assembly Manual filling: • Perform filling of the lubricant reservoir carefully and stop once the “MAX fill level” (sight glass on lubricant discharge from the pressure lubricant reservoir) or electrical max. - Page 12 Page 12 Assembly instructions Residual risk Remedy Life cycle: Setup, retrofit Risk of slipping due to contamination of floor by • Proceed carefully when filling the lubricant reservoir using a filler coupling. spilled or leaked lubricant • Promptly apply suitable binding agents and remove the leaked or spilled lubricant. •...
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Page 13: Lubricants
EC Directive 67/548/EEC, Article 2, Para. 2, the selection of components and the design of chine/system in cooperation with the lubricant may only be filled into SKF centralized lubrication centralized lubrication systems. supplier. When selecting a lubricant, the type systems and components and delivered and/or... -
Page 14: Approved Lubricants
The product described here can be operated You can request an overview of the lubricant using lubricants that meet the specifications in tests offered by SKF from the company's Sales the technical data. department. Note that in rare cases, there may be lubri-... -
Page 15: Lubricants And The Environment
Assembly instructions Page 15 Approved oils, Table 1 Consult the safety data sheet from the lubri- Lubricant leaking from centralized lubrication cant manufacturer for information regarding systems is a serious hazard. Leaking lubricant Requirement Values transport, storage, processing, and environ- can create risks that may result in physical Recommended 13/10 (ISO 4406) -
Page 16: Overview
Page 16 Assembly instructions 3. Overview Overview of the SKF microdosage system Application example of the microdosage system on a machine tool Legend Item Description Chapter 1 MDR lubricant reservoir 1a Electr. fill level switch 4.3.3 1b Max. fill level sight glass 1c Compressed air connection 4.5-10 bar... -
Page 17: Mdu Micro-Metering Unit
Assembly instructions Page 17 Overview of MDU micro-metering unit Components of the MDU micro-metering unit MDU micro-metering unit Item Description Chapter MDU micro-metering unit Power supply LED (green power LED) LED enable signal (yellow enable LED) OI/Chap. 6 Error notification LED (red error LED) LEDs for outlet 1 to outlet 4 (OUT1- OUT4) Push connector/connecting cable for lubricant feed 4.4. -
Page 18: Mdr Lubricant Reservoir Designs
Page 18 Assembly instructions Overview of MDR lubricant reservoir designs Components of an MDR lubricant reservoir MDR lubricant reservoir Examples of various connectivity options, Item Description Chapter area of inlet/outlet/filling MDR lubricant reservoir 4.3.1 Vent plug 4.3.4 Electrical fill level monitoring 4.3.3 Compressed air control valve Compressed air input port... -
Page 19: Assembly
MDS system must be vented carefully. sequence: and avoid potential hazards. The definition of trained personnel and the A feature of the MDS microdosage system is MDR lubricant reservoir(Chapter 4.3) Attachment of MDR lubricant reservoir prohibition of employing non-qualified per- its ease of use. -
Page 20: Setup And Attachment
These documents can also be down- Follow the safety instructions on the lines. Ensure that no dust particles loaded from the homepage of SKF lubricant's safety data sheet. enter the metering system. Lubrication Systems Germany GmbH. -
Page 21: Mdr Lubricant Reservoir
Assembly instructions Page 21 MDR lubricant reservoir The lubricant reservoir should be installed in a Lubricant and compressed air are separated o Other units must not be damaged by freely accessible area to allow for manual fill- assembly work. from each other by a dividing piston, so a ing and visibility of both sight glasses (fill level compressed air filter is not required. -
Page 22: Attachment Of Mdr Lubricant Reservoir
Page 22 Assembly instructions 4.3.1 Attachment of MDR lubricant reservoir 4.3.2 Assembly drawing with minimum installation dimensions See Figure 1 Mounting dimensions for MDR lubricant reservoir, Fig. 1 Installing the lubricant reservoir Note! • Drill assembly holes (Ø 9 mm, 4x) (1) on To ensure that the microdosage the surface provided by the customer system functions reliably, the pres-... -
Page 23: Electrical Fill Level Indicator
Assembly instructions Page 23 4.3.3 Electrical fill level indicator 4.3.4 Initial filling and venting of the MDR lubricant reservoir See Figure 2 See Figure 3 • Connect the filling device (e.g., hand pump) (6) and fill up to the start of the maximum To ensure that the micro-metering unit func- •... - Page 24 Page 24 Assembly instructions Venting the MDR, Fig. 3 • Clamp/close the vent hose above the level of the socket wrench. Compressed air feed must not be connected! • Pull off and remove vent hose (9) and socket wrench (3). •...
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Page 25: Connecting Compressed Air Connection
O-ring (2) lubricant reservoir comes standard with an and the locking claw (5) of the collet (4) and SKF plug connector for a 6 mm tube. The reaches the mechanical stop (3). compressed air line (provided by customer) is connected as described below. -
Page 26: Mdu Micro-Metering Unit
To ensure enough space for maintenance work onto the connector plug (2) of the MDU, to the Figure 5 below. and for possible disassembly of the SKF mi- then align and tighten by hand. crodosage system, ensure that the minimum During assembly and especially when drilling, mounting dimensions (Fig. -
Page 27: Assembly Drawing With Minimum Installation Dimensions
Assembly instructions Page 27 4.4.2 Assembly drawing with minimum installation dimensions Assembly drawing of the MDU micro-metering unit, Fig. 5 10,5 SKF Lubrication Systems Germany AG 24 VDC Error Power Enable Enable OUT 1 OUT 2 OUT 3 OUT 4... - Page 28 Page 28 Assembly instructions Note! Electrical connection, Fig. 6 Use functional extra-low voltage with safe isolation according to standard DIN EN 60204-1 / IEC/60204-1. 24 VDC Connecting When establishing the MDU micro- me- coupling (2) Error tering unit’s electrical connection, ensu- Enable re that appropriate measures prevent interference between signals due to...
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Page 29: Capillary Line Connection
Assembly instructions Page 29 4.4.3 Capillary line connection See Figure 7 The lubricant feed line must not escape The capillary line is not included with the from the plug connector. MDU and must be ordered separately as an accessory (see “Accessories” chapter). •... -
Page 30: Arrangement Of Capillary Lines
MDR lubricant reservoir must be connected to the metering unit in • Connect main lubricant line to SKF plug • Arrange capillary line (9) to the lubrication such a way that no forces can be transferred connector. -
Page 31: Venting The Main Lubricant Line And Mdu Micro-Metering Unit
Assembly instructions Page 31 4.5.1 Venting the main lubricant line and MDU micro-metering unit See Figure 9 o Place the oil pan under the MDU, extend immediately attach the loose end of the lubricant line to the plug connector of the the loose end of the main lubricant line Requirements: (connection to MDU) into the pan. - Page 32 This is testing oil what was used in the factory inspection of the MDU. • Use an absorbent cloth to remove discharged oil; remove oil residues using a cloth. SKF Lubrication Systems Germany AG 24 VDC Error Power Enable Enable...
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Page 33: Note On The Rating Plate
Page 33 Note on the rating plate 4.6.1 MDU rating plate The rating plate of the MDU micro-metering SKF Lubrication Systems Germany GmbH unit and the MDR lubricant reservoir provides Type designation important key data such as type designation Serial number and serial number (or customer number). -
Page 35: Microdosage System (Mds)
Microdosage system (MDS) Operating instructions associated with assembly instructions for continuous lubrication of high-speed spindles with minimum quantities of oil from 0.5 to 5 mm /min... -
Page 36: Safety Instructions
Caused by the installation of non-original In addition to the operating instructions, SKF components or SKF spare parts general statutory regulations and other o Caused by inappropriate usage regulations for accident prevention o Resulting from improper assembly,... -
Page 37: Transport, Delivery, And Storage
Page 37 3. Transport, delivery, and storage Lubrication units General information on storage SKF Lubrication Systems Germany GmbH products are packaged in accordance with o Ambient conditions: dry and dust-free o The product(s) can be enveloped in plastic film to provide low-dust storage. -
Page 38: Assembly
The tube threads indicated in Figure 1 are General suitable for connecting the capillary lines on SW 7 The microdosage system can be used for con- the spindle and bearing. tinuous and highly accurate metering of small quantities of lubricant. - Page 39 4. Assembly Page 39 The lubricant ducts inside a spindle and to the roller bearings, the lubricant should be intro- Lubricant feeding for vertical and horizontal duced into the rolling bearing from both sides bearing lubrication points should meet the fol- mounting position and rotating inner ring, Fig.
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Page 40: Lubricant Quantity
Lubrication of bearing running surfaces with Lubricant feeding via outer ring, Fig. 3 a bearing depends on the type of bearing, the microdosage system is more efficient number of rows, width, etc. compared to oil+air lubrication. Almost 100% In principle, the bearing manufacturer should... -
Page 41: Filling Lubricant Ducts In The Spindle
4. Assembly Page 41 4.2.3 Filling lubricant ducts in the spindle Within the spindle, there are lubricant ducts 2. The volumetric flow provided by the micro- If the volumetric oil flow in filling mode is not available or only very small volumes are to be through which the lubricant is transported dosage system in filling mode depends on from the connecting points on the spindle to... -
Page 42: Design And Function
The system’s components perform the follow- The system components are connected via the ing tasks: main lubricant line (3). The SKF microdosage system is an intelligent micro-metering system for especially de- manding applications. It feeds lubricant to the MDR lubricant reservoir (1) -
Page 43: Principle Of The Skf Microdosage System
See Figure 4 bricant flow at the respective outlet is checked PLC or machine control unit. The MDU contin- The SKF microdosage system consists of two for adherence the defined tolerances according ues metering option despite limitations and main components, the lubricant reservoir to the settings. - Page 44 Page 44 5. Design and function o Clogged line to the lubrication point SKF microdosage system, Fig. 4 o Deviations from the operating temperature range MDU micro-metering unit MDR lubricant reservoir o Error in a metering valve o Error in the flow sensor...
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Page 45: Operation
6. Operation Page 45 6. Operation General information The fill level of the lubricant in the lubricant The MDU is subjected to an inspection Note! reservoir should be subjected to visual in- and adjustment using colored lubricant Only fill using clean lubricant and an spection at regular intervals. If the lubricant at the factory. -
Page 46: Microdosage System Parameters
Page 46 6. Operation Microdosage system parameters Legend to Fig. 5 MDU adjustment elements, Fig. 5 WAF 1 DIP switches S1 to S4 (description in Chapter 4.5.1, adjusting table A) System configuration Quantity reduction of 1:10 S1 off Volumetric flow 0.5 to 5.0 µl/min S1 on Volumetric flow 0.05 to 0.5 µl/min... -
Page 47: Configuring The System
6. Operation Page 47 6.2.1 Configuring the system 6.2.2 Determining quantity of lubricant Table A Table B Function/operating mode Switch position Configuration of Rotary switch (S1 to S4) lubricant quantity [Switch position [S1] [S2] [S3] [S4] (SV1 to SV4) Condition on delivery/default setting µl/min Time slot Lubrication system... -
Page 48: Commissioning/Venting The System
Page 48 6. Operation Commissioning/venting the system 6.3.1 Venting the system See Figure 6 Light guides for the LED display are con- See Figures 5 and 7 A requirement for commissioning is that the tained on the inner part of lid of the metering Next, vent the valves and fill the capillary lines. - Page 49 6. Operation Page 49 Example of air dissolved in oil, Fig. 6 o If the switches for multiple outlets are in non-pressurized capillary line. position “F”, the filling procedure is started for the next outlet with the smallest number o The filling procedure must be repeated if immediately after the active outlet is stopped.
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Page 50: Filling Spindle Lubricant Ducts
Page 50 6. Operation 6.3.2 Filling spindle lubricant ducts See Chapter 4.2.3 Adjustment elements, Fig. 7 To conclude, the lubricant ducts within the spindle are individually filled with lubricant. The procedure is analogous to filling capillary lines. Filling is activated using switch position “F”... -
Page 51: Calibration Of The System
6. Operation Page 51 Calibration of the system See Figures 5 and 7 i.e., when the enable LED (yellow) is lit. During commissioning, it is recommended that 6.4.1 General a manual calibration be performed with up to 3 cycles. This quickly achieves a high level of The MDU has a calibration function that is 6.4.2 Manual calibration accuracy for the volumetric flow under the... -
Page 52: External Adjustment Of Volumetric Flow
Page 52 6. Operation 6.4.3 Automatic calibration External adjustment of volumetric flow See Figures 8 to 10 Automatic calibration begins during operation Enable signal, Fig. 8 for all active outlets if a corresponding event The machining parameters of machine tool occurs (Table 1, page 44). - Page 53 6. Operation Page 53 To reduce the volumetric flow to one-third or Enable signal, Fig. 9 Enable signal, Fig. 10 one-half (for example), the enable signal must be set to OFF for one third or one-half of the lubrication time (runtime), respectively (see Figure 9 and Fig.
- Page 54 Page 54 6. Operation Defining the cycle times: Table C See Table C Cycle times for reducing volumetric flow via the enable signal The time the MDU requires for all outlets to deliver lubricant once is referred to as the cy- Cycle times for enable signal Effective volumetric flow cle time.
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Page 55: Shutdown And Disposal
To recommission the product, follow the in- structions in the "Assembly instructions" and The product can also be returned to "Commissioning" chapters in these assembly SKF Lubrication Systems Germany instructions. GmbH for disposal, in which case the customer is responsible for reimbursing the costs incurred. -
Page 56: Maintenance And Service
If this occurs, plication. The criteria are machine-specific products are low-maintenance. However, all please contact the Service department of SKF settings, ambient and operating conditions, connections and fittings must be regularly in- Lubrication Systems Germany GmbH for... -
Page 57: Maintenance And Repair
8. Maintenance and service Page 57 Maintenance and repair The following maintenance and repair work SKF Lubrication Systems Germany GmbH must be performed on a regular basis: shall not be held liable for damages resulting from improperly performed assembly, mainte- Inspect the main lubricant line and the nance or repair work on the product. -
Page 58: Malfunctions
All assembly, maintenance and repair switched off before opening any of the work beyond this scope must be perfor- product's components. med by the Service department of SKF Lubrication Systems Germany GmbH. Danger! Only original spare parts from SKF Centralized lubrication systems are Lubrication Systems Germany GmbH pressurized during operation. -
Page 59: Malfunctions, Causes, And Remedies
Question Answer What happens if the compressed air The microdosage system typically functions properly even with a somewhat lower compressed air supply for the lubricant reservoir is supply. The automatic calibration compensates for changes in operating parameters such as tempe- below 4 bar and is only 3.5 bar? - Page 60 Yes, this is mandatory. It is absolutely essential to the proper functioning of the the capillary lines? microdosage system that the oil fed from the lubricant reservoir (MDR) is free of air pockets. The system is not completely vented if air pockets are visible in the capillary lines.
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Page 61: Technical Data
10. Technical data Page 61 10. Technical data 10.1 MDU micro-metering unit 10.2 MDR lubricant reservoir Technical data, Table 4 Technical data, Table 5 Designation Designation Temperature range -10°C to +70°C Dimensions (WxLxH) 110 x 313 x 360 mm Mounting position Contents 1 liter Dimensions (WxLxD) -
Page 62: Accessories
11. Accessories Page 62 11. Accessories Accessories Item Designation Order No. Mounting rail 886-570-005 Cable socket M12x1, straight 179-990-371 Cable socket M12x1, straight with cable 5 m 179-990-600 1/16” adapter, plastic 169-510-017 (see page 29, item 5) 1/16” ferrule (sleeve) and clamp ring 169-510-018 Tube 1/16”, 5 m 167-002-010... - Page 63 Page 63...
- Page 64 All SKF products may be used only for their intended purpose as described in these assembly instructions with associated operating instructions. If assembly/operating instructions are supplied together with the products, they must be read and followed.
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