SKF UFD20 Series Assembly Instructions Manual
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SKF UFD20 Series Assembly Instructions Manual

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DigitalSuper
of series UFD10 and UFD20
Minimal quantity lubrication system for internal lubrication
Version 06
951-170-218-EN
Assembly instructions
acc. to Machinery Directive 2006/42/EC
EN

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  • Page 1 Assembly instructions DigitalSuper acc. to Machinery Directive 2006/42/EC of series UFD10 and UFD20 Minimal quantity lubrication system for internal lubrication Version 06 951-170-218-EN...

  • Page 2: Ec Declaration Of Incorporation

    EC Declaration of Incorporation EC Declaration of Incorporation acc. to Machinery Directive 2006/42/EC, Appendix II Part 1 B The manufacturer, SKF Lubrication Systems Germany GmbH, Berlin Plant, Motzener Straße 35 -37, DE - 12277 Berlin, hereby declares conformity of the partly completed machinery...
  • Page 3 Training SKF Lubrication Systems Germany GmbH The manufacturer shall not be held liable for Addresses of manufacturer plants SKF conducts detailed training in order to damage resulting from: Headquarters enable the maximum safety and efficiency. ○ Improper usage, assembly, operation,...

  • Page 4: Table Of Contents

    Table of contents Table of contents EC Declaration of Incorporation ................2 Explanation of symbols and signs ................ 7 Lubricants ................18 General information ................18 Selection of lubricants ................18 Material compatibility ................19 Safety instructions ..............9 Aging of lubricants ................19 General safety instructions ..............
  • Page 5 6.8.4 UFD10-1-20000 / UFD10-1-201000..........80 6.8.5 UFD10-1-110000 / UFD10-1-111000 ..........81 Return shipment ...................60 6.8.6 UFD10-1-210000 / UFD10-1-211000 ..........82 Storage ....................60 6.8.7 Customer connectivity with an optional SKF Assembly ................61 aerosol monitor (AM1000) ..............83 General information ................61 Pneumatic connection .................84 Assembly location .................61 Mechanical connection .................62...
  • Page 6 Table of contents Commissioning/Operation ..........107 Shutdown, disposal ............126 Initial filling ..................107 13.1 Temporary shutdown ................ 126 9.1.1 Depressurizing the aerosol generator ..........107 13.2 Extended shutdown ................126 Manual filling ..................108 13.3 Permanent shutdown, disassembly ..........126 Automatic filling .................

  • Page 7: Explanation Of Symbols And Signs

    Explanation of symbols, signs, and abbreviations Explanation of symbols and signs General warning Risk of electrical shock Risk of slipping Hot surfaces Being drawn into machinery Crushing hazard Pressure injection Suspended load Electrostatic sensitive Potentially explosive Disposal of waste electrical and Disposal, recycling components atmosphere...
  • Page 8 Explanation of symbols, signs, and abbreviations Abbreviations and conversion factors regarding °C degrees Celsius °F degrees Fahrenheit approx. approximately Kelvin ounce i.e. that is Newton fl. oz. Fluid ounce etc. et cetera hour inch poss. possibly second pound per square inch incl.

  • Page 9: Safety Instructions

    1. Safety instructions 1. Safety instructions 1.1 General safety instructions 1.2 General behavior when handling the product ○ The operator must ensure that the in- ○ Protective and safety mechanisms must ○ The product may only be used in aware- structions are read by all persons tasked not be removed, modified, nor disabled with working on the product or who...

  • Page 10: Intended Use

    1. Safety instructions 1.3 Intended use 1.4 Foreseeable misuse ○ Use to feed, forward, or store hazardous The minimal quantity lubrication (MQL) Any usage of the product other than as systems of the series UFD10 and UFD20 specified in this manual is strictly prohibited. substances and mixtures as defined in were designed for internal lubrication of Particularly prohibited are:...

  • Page 11: Modifications To The Product

    1. Safety instructions 1.5 Modiications to the product 1.7 Referenced documents 1.8 Notes on the rating plate Unauthorized modifications and changes In addition to this manual, the following The rating plate provides important data can have an unpredictable effect on safety. documents must be observed by the re- such as the type designation and material Unauthorized modifications and changes...

  • Page 12: Note On Ce Marking

    1. Safety instructions 1.9 Note on CE marking 1.10 Persons authorized to use the 1.10.3 Qualiied electrician product The CE marking is based on the require- A person with appropriate technical training, ments of the applied Directives: 1.10.1 Operator knowledge, and experience who can recog- A person competent due to training, knowl- nize and avoid the hazards that may result ○...

  • Page 13: Provision Of Personal Protective Gear

    1. Safety instructions 1.12 Provision of personal protective 1.13 Operation 1.15 Transport, assembly, maintenance, gear malfunction, repair, shutdown, disposal The following must be observed during ○ All relevant persons must be informed of The operator must provide personal protec- commissioning and operation: tive gear appropriate for the location and the activity prior to the start of this work.
  • Page 14 1. Safety instructions ○ Take appropriate measures to ensure ○ All components used must be designed tools suitable for electrical work. that moving, detached parts are immo- for: ○ Establish the electrical connection only in bilized during the work and that no limbs - The maximum operating pressure can be pinched by unintended move- accordance with the valid circuit diagram...

  • Page 15: Initial Commissioning, Daily Startup

    1. Safety instructions 1.16 Initial commissioning, daily startup 1.17 Cleaning ○ Avoid mixing up/incorrectly assembling ○ There is a fire hazard from the use of disassembled parts. Label parts. Ensure that: flammable cleaning agents. Use only non-flammable cleaning agents that are ○...

  • Page 16: Residual Risks

    1. Safety instructions 1.18 Residual risks Possible in Residual risk Avoidance / Remedy lifecycle Unauthorized persons must be kept away. Nobody is allowed to be present below hoisted parts. Personal injury / property damage due A, B, C, Lift parts using suitable and tested lifting gear. Ensure adequate fastening/securing of the unit to falling of hoisted parts G, H, K (loading capacity).
  • Page 17 1. Safety instructions Possible in Residual risk Avoidance / Remedy lifecycle The minimal quantity lubrication system must be depressurized before maintenance work Overpressure at reservoir, filter, screw unions, and lines is performed. Exercise caution when filling and when closing the screw plug of the filler socket. Promptly Personal injury / property damage due B, C, D, F, apply suitable binding agents and remove the spilled lubricant.

  • Page 18: Lubricants

    2. Lubricants 2.1 General information 2.2 Selection of lubricants Lubricants are used specially for specific SKF Lubrication Systems considers lubri- Only lubricants specified for the applications. To fulfill the task, lubricants cants to be an element of system design. product may be used (see “Tech-...

  • Page 19: Material Compatibility

    It is possible for lubricants to be tested in the company's laboratory for their suitability for pumping in centralized lubrication systems (e.g., "bleeding"). Please contact SKF if you have further ques- tions regarding lubricants. An overview of the lubricants we have tested is available on request.

  • Page 20: Overview, Functional Description

    In terms of the size and distribution of lubri- Using compressed air, the aerosol produced required. cant droplets created, the SKF MQL system in the lubricant reservoir is transported via The actual lubrication is performed at the described here generates a very homoge-...
  • Page 21 The DigitalSuper minimal quantity lubrica- refilling reservoir supplied by the customer tion system is controlled via a communica- (SKF reservoir according to customer re- tion interface to the machine tool. The inter- quirements). The pump is switched on and face is implemented as a fieldbus connection off by the control unit of the MQL system.

  • Page 22: Main Components Of A Ufd Minimal Quantity Lubrication System

    Ball valve (pages 38 to 57). Tool spindle 3.4.1 Aerosol generator The heart of the SKF MQL system is the aerosol generator, which consists of various air and lubricant nozzles. The nozzles are installed in a reservoir that both stores the required lubricant and collects the gener- ated aerosol.

  • Page 23: Control Unit

    3. Overview, functional description 3.4.2 Control unit The MQL system is controlled and moni- The following are monitored: The MQL control unit can exchange data ○ The fill level in the lubricant reservoir tored by an integrated control unit, whereas with the machine tool’s control unit via a ○...

  • Page 24: Communication Interface

    3. Overview, functional description 3.4.3 Communication interface 3.4.5 Fill level indicator and monitoring 3.4.6 Main air valve See item 13 See item 4 (compressed air connection) See item 7 The DigitalSuper minimal quantity lubrica- The lubricant level in the reservoir is contin- tion system is controlled via a communica- uously monitored by the control unit using a The main air valve is located immediately...

  • Page 25: Pressure Gauge

    3. Overview, functional description 3.4.7 Pressure gauge 3.4.8 Fine ilter for compressed air 3.4.9 Lubricant drain valve See items 5/6 See item 11 See item 8 For each aerosol generator in the system, The compressed air supply of the system is The lubricant in the reservoir can be two pressure gauges are installed in the equipped with a fine air filter that ensures...

  • Page 26: Design-Specific Components

    3. Overview, functional description 3.5 Design-speciic components 3.5.1 PROFIBUS communication interface See Figure 3 Fieldbus coupler, Fig. 3 Legend to Fig. 3 MQL systems with PROFIBUS interface Plug Function H1 = Green LED (PROFIBUS) come with a PROFIBUS fieldbus coupler H2 = Red LED (PROFIBUS) H1/H2 Indicate the status of the...
  • Page 27 3. Overview, functional description Connection states, Table 1, 1 of 2 Connection to bus Connection to MQL system State/cause Green LED Red LED Green LED Red LED Power supply not present Flashes Flashes Flashes Flashes Fieldbus coupler is conducting self-test Fieldbus coupler is waiting for the MQL system to send its coniguration data Flashes (number of input/output bytes, number of parameter bytes, data transfer...
  • Page 28 3. Overview, functional description Connection states, Table 1, 2 of 2 Connection to MQL Connection to bus system State/cause Green LED Red LED Green LED Red LED Fault: Fieldbus coupler is ready to operate but is not addressed by the bus master or the coniguration sent by the bus master does not match the coniguration of the MQL system.

  • Page 29: Profinet Communication Interface

    3. Overview, functional description 3.5.2 PROFINET communication interface See Figure 4 MQL systems in designs UFD10-1-2XX000 PROXY connections, Fig. 4 can be operated on a PROFINET I/O controller via a gateway. The gateway is installed either in a sepa- rate switchbox or in the bypass control switchbox.
  • Page 30 3. Overview, functional description PROXY connection states, Table 2 (1 of 2) System LEDs LED Dual LED LED color Status/state Meaning Green Firmware started This state should only occur briefly. Yellow If the LED remains yellow, this may indicate a hardware defect. green/ Blinking Bootloader active...
  • Page 31 3. Overview, functional description PROXY connection states, Table 2 (2 of 2) LEDs on PROFIBUS DP Master LED Dual LED LED color Status/state Meaning Green Flashing acyclically No configuration, or stack error. PROFIBUS is configured but bus communication not yet enabled by the Green Flashing cyclically application.

  • Page 32: Automatic Filling Pump

    (SKF reservoir according to customer re- the increasing borehole depth impedes the Lubrication program number 50 is used to quirements). The pump is switched on and aerosol flow.
  • Page 33 Changes to the bypass control are typically ized, leading to closure of the directional ball not necessary and should be made only valve. for special applications by SKF application specialists. If these keys are accidentally pressed, press the « » cursor key and then the «ESC»...
  • Page 34 3. Overview, functional description The control unit for the bypass valve has an Display 1: Inlet pressure and aerosol res- Menu, Fig. 6 information display that provides informa- ervoir internal pressure in bar tion on pressure conditions in the system. Display 2: Bar diagram of inlet pressure After switch on the operating voltage, the and internal pressure in aerosol...

  • Page 35: System Designs And Type Codes

    3. Overview, functional description 3.6 System designs and type codes System overview, Fig. 7 Minimal quantity lubrication system (MMS) Digital Super System overview Minimal quantity lubrication systems with one aerosol generator UFD10-1-XXX000 PROFIBUS PROFINET PROFIBUS UFD10-1-100000 UFD10-1-200000 UFD20-1-100000 with bypass control with filling pump with bypass control with filling pump...
  • Page 36 3. Overview, functional description Type codes for UFD10 UFD 10 - Order example: Type designation UFD Number of aerosol generators 10 = 1 aerosol generator (UFD10) Generation 1 = 1st generation Date transmission 1 = PROFIBUS (PB) 2 = PROFINET (PN) Bypass control system (BPC) 0 = Without bypass control 1 = With bypass control...
  • Page 37 3. Overview, functional description Type codes for UFD20 UFD 20 - Order example: Type designation UFD Number of aerosol generators 20 = 2 aerosol generators (UFD20) Generation 1 = 1st generation Date transmission 1 = PROFIBUS (PB) Bypass control system (BPC) 0 = Without bypass control Filling pump (FLP) 0 = Without integrated filling pump...

  • Page 38: Minimal Quantity Lubrication Systems With One Aerosol Generator

    3. Overview, functional description 3.6.1 Minimal quantity lubrication systems with one aerosol generator 3.6.1.1 UFD10-1-100000 System design UFD10-1-100000, Fig. 8 Aerosol line Compressed air supply Ball valve Internal control unit Aerosol Tool spindle generator Items Machine control unit ○ One aerosol generator ○...
  • Page 39 3. Overview, functional description UFD10 with PROFIBUS, Fig. 9 Item Description Control cabinet housing Connections for aerosol lines View A (for max. of three spindles) Screw plug for manual filling Fill level indicator Pressure gauge for internal reservoir 1500 1400 1300 1200 pressure...
  • Page 40 3. Overview, functional description 3.6.1.2 UFD10-1-101000 System design UFD10-1-101000, Fig. 10 Aerosol line Compressed air supply Ball valve Tool spindle Internal control unit Aerosol generator Filler pump Items Machine control unit ○ One aerosol generator ○ PROFIBUS interface Tool ○ With integrated filling pump Refilling reservoir Fieldbus (optional)
  • Page 41 3. Overview, functional description UFD10 with PROFIBUS and filling pump, Fig. 11 Item Description Control cabinet housing 2 10 Connections for aerosol lines View A (for max. of three spindles) Screw plug for manual filling Fill level indicator 1500 1400 1300 1200 Pressure gauge for internal reservoir...
  • Page 42 3. Overview, functional description 3.6.1.3 UFD10-1-1100000 System design UFD10-1-110000, Fig. 12 Aerosol line Y-distributor Compressed air supply Ball valve Ball valve Internal Bypass control Control unit Aerosol Tool generator spindle Bypass restrictor Machine control unit Items Tool ○ One aerosol generator Fieldbus ○...
  • Page 43 3. Overview, functional description Item Description UFD10 with PROFIBUS and bypass control, Fig. 13 View A Control cabinet housing Connections for aerosol lines (for max. of three spindles) Screw plug for manual filling Fill level indicator Pressure gauge for internal reservoir View B pressure Bypass Valve...
  • Page 44 3. Overview, functional description 3.6.1.4 UFD10-1-111000 System design UFD10-1-111000, Fig. 14 Aerosol line Compressed air supply Y-distributor Ball valve Ball valve Internal Bypass control Control unit Tool Aerosol spindle generator Bypass restrictor Filler pump Items ○ One aerosol generator Machine control unit ○...
  • Page 45 3. Overview, functional description Item Description , Fig. 15 UFD10 with PROFIBUS, bypass control, and filling pump View A Control cabinet housing Connections for aerosol lines (for max. of three spindles) Screw plug for manual illing Fill level indicator Pressure gauge for internal reservoir View B pressure Bypass Valve...
  • Page 46 3. Overview, functional description 3.6.1.5 UFD10-1-200000 System design UFD10-1-200000, Fig. 16 Aerosol line Compressed air supply Ball valve Internal control unit Aerosol Tool generator spindle Machine control unit Items Tool ○ One aerosol generator ○ PROFINET interface Fieldbus - 46 - 951-170-218-EN Version 06...
  • Page 47 3. Overview, functional description UFD10 with PROFINET, Fig. 17 Item Description Control cabinet housing Connections for aerosol lines (for max. of View A three spindles) Screw plug for manual filling Fill level indicator 1500 Pressure gauge for internal reservoir 1400 1300 1200 1100...
  • Page 48 3. Overview, functional description 3.6.1.6 UFD10-1-201000 System design UFD10-1-201000, Fig. 18 Aerosol line Compressed air supply Ball valve Internal control unit Tool spindle Aerosol generator Filler pump Machine control unit Items Tool ○ One aerosol generator Refilling reservoir ○ PROFINET interface Fieldbus (optional) ○...
  • Page 49 3. Overview, functional description Item Description UFD10 with PROFINET and filling pump, Fig. 19 1 Control cabinet housing 2 Connections for aerosol lines (for max. of View A three spindles) 3 Screw plug for manual filling 4 Fill level indicator 1500 1400 1300...
  • Page 50 3. Overview, functional description 3.6.1.7 UFD10-1-210000 System design UFD10-1-210000, Fig. 20 Y-distributor Aerosol line Compressed air supply Ball valve Ball valve Internal Bypass control Control unit Aerosol Tool spindle generator Bypass restrictor Machine control unit Tool Items Fieldbus ○ One aerosol generator ○...
  • Page 51 3. Overview, functional description Item Description UFD10 with PROFINET and bypass control, Fig. 21 View A Control cabinet housing Connections for aerosol lines (for max. of three spindles) Screw plug for manual illing Fill level indicator Pressure gauge for internal reservoir View B Bypass Valve Ball Valve...
  • Page 52 3. Overview, functional description 3.6.1.8 UFD10-1-211000 System design UFD10-1-211000, Fig. 22 Aerosol line Y-distributor Compressed air supply Ball valve Ball valve Internal Bypass control Control unit Tool Aerosol spindle generator Bypass restrictor Filler pump Items ○ One aerosol generator Machine control unit ○...
  • Page 53 3. Overview, functional description Item Description UFD10 with PROFINET, bypass control, and filling pump, Fig. 23 View A Control cabinet housing Connections for aerosol lines (for max. of three spindles) Screw plug for manual illing Fill level indicator Pressure gauge for internal reservoir View B pressure Bypass Valve...

  • Page 54: Minimal Quantity Lubrication Systems With Two Aerosol Generators

    3. Overview, functional description 3.6.2 Minimal quantity lubrication systems with two aerosol generators 3.6.2.1 UFD20-1-100000 System design UFD20-1-100000, Fig. 24 Compressed air supply Compressed air supply Aerosol line Aerosol line Ball valve Ball valve Internal Internal control control unit unit Tool Aerosol Aerosol...
  • Page 55 3. Overview, functional description UFD20 with PROFIBUS, Fig. 25 Item Description View A Control cabinet housing 2 10 2 10 Connections for aerosol lines (for max. of three spindles) Screw plug for manual illing Fill level indicator Pressure gauge for internal reservoir 1500 1400 Max.
  • Page 56 3. Overview, functional description 3.6.2.2 UFD20-1-101000 System design UFD20-1-101000, Fig. 26 Compressed air supply Compressed air supply Aerosol line Aerosol line Ball valve Ball valve Internal Internal control control Tool Tool unit unit Aerosol Aerosol spindle spindle generator generator Filler Filler pump pump...
  • Page 57 3. Overview, functional description UFD20 with PROFIBUS, Fig. 27 Item Description View A Control cabinet housing Connections for aerosol lines 2 10 2 10 (for max. of three spindles) Screw plug for manual filling Fill level indicator Pressure gauge for internal reservoir pressure 1500 1400...

  • Page 58: Technical Data

    4. Technical data 4. Technical data 4.1 General technical data Technical data, Table 3 (1 of 2) Universal data Key data / indicator Designation UFD10-1-XXX000 UFD20-1-XXX000 Mounting position Vertical, connections downward Reservoir capacity, utilizable 1.2 liter Permissible operating pressure/ambient + 10°C to +40°C temperature Lubricant See approval list...
  • Page 59 4. Technical data Technical data, Table 3 (2 of 2) Universal data Key data / indicator Designation UFD10-1-XXX000 UFD20-1-XXX000 Connection for aerosol line Plug connector for plastic tube 12x1 Automatic lubricant refill Connection for suction line Plug connector for plastic tube Pa11/12 plastic tube 10x1.5 Connection for return / reservoir drainage Plug connector for plastic tube Pa11/12 plastic tube 10x1.5 Connection for aerosol line...

  • Page 60: Delivery, Returns, Storage

    5. Delivery, returns, storage 5. Delivery, returns, storage 5.1 Delivery The following conditions apply to storage: After receipt of the shipment, it must be The following must be marked on the pack- ○ Maximum storage time of 24 months inspected for any shipping damage and for aging of return shipments: ○...

  • Page 61: Assembly

    6. Assembly 6. Assembly 6.1 General information 6.2 Assembly location Before assembling/setting up the minimal The MQL system should be mounted so During assembly and especially when drill- quantity lubrication systems, referred to that it is protected from humidity and vibra- ing, always pay attention to the following: in the following as the MQL system, the tion but is also easily accessible, allowing all...

  • Page 62: Mechanical Connection

    6. Assembly 6.3 Mechanical connection and accident prevention. o Set software configuration in the machine IMPORTANT NOTE control unit ○ Any existing visual monitoring equipment such as pressure gauges, min./max. For proper functioning, the system must be markings, oil sight glasses, etc. must be installed vertically.

  • Page 63: Minimum Mounting Dimensions

    6. Assembly 6.3.1 Minimum mounting dimensions 6.5 Assembly holes 6.5.1 Attaching MQL systems See Figures 28 to 32 To ensure enough space for maintenance work and for any disassembly of the MQL The MQL system is installed on the machine •...

  • Page 64: Minimum Installation And Mounting Dimensions

    6. Assembly Minimum installation and mounting dimensions 6.6.1 MQL UFD10-1-100000 and UFD10-1-101000 UFD10-1-1-100000 and UFD10-1-101000, Fig. 28 4xØ8,2 Drilling template 4x 8,2 1500 1400 1300 1200 1100 1000 AEROSOL System 1 System 1 3 4 5 6 PARAMETER System 1 Minimum mounting dimensions/clearance [mm] Height...

  • Page 65: Mql Ufd10-1-200000 And Ufd10-1-201000

    6. Assembly 6.6.2 MQL UFD10-1-200000 and UFD10-1-201000 UFD10-1-1-200000 and UFD10-1-201000, Fig. 29 4x 8,2 Drilling template 4x 8,2 1500 1400 1300 1200 1100 1000 AEROSOL System 1 System 1 3 4 5 6 PARAMETER System 1 Minimum mounting dimensions/clearance [mm] Power UFD10 Height...

  • Page 66: Mql Ufd10-1-110000 And Ufd10-1-111000

    6. Assembly 6.6.3 MQL UFD10-1-110000 and UFD10-1-111000 UFD10-1-110000 / UFD10-1-111000, Fig. 30 Drilling template 4xØ8,2 4x 8,2 1500 1400 1300 1200 1100 1000 AEROSOL System 1 System 1 3 4 5 6 PARAMETER System 1 Minimum mounting dimensions/clearance [mm] Height 1000 Width ca.

  • Page 67: Mql Ufd10-1-210000 And Ufd10-1-211000

    6. Assembly 6.6.4 MQL UFD10-1-210000 and UFD10-1-211000 UFD10-1-210000 / UFD10-1-211000, Fig. 31 Drilling template 4xØ8,2 4x 8,2 1500 1400 1300 1200 1100 1000 AEROSOL System 1 System 1 3 4 5 6 PARAMETER System 1 Minimum mounting dimensions/clearance [mm] Height 1000 Width Depth...

  • Page 68: Mql Ufd20-1-100000 And Ufd20-1-101000

    6. Assembly 6.6.5 MQL UFD20-1-100000 and UFD20-1-101000 UFD20-1-1-100000 and UFD20-1-101000, Fig. 32 Drilling template 4x 8,2 4x 8,2 1500 1400 1300 Max. - max. 1200 1100 1000 AEROSOL AEROSOL System 1 System 2 System 1 System 2 1 2 3 4 5 6 7 PARAMETER PARAMETER...

  • Page 69: Connection Of Aerosol Lines

    6. Assembly 6.7 Connection of aerosol lines 6.7.1 General notes on the connection of aerosol lines See Figure 33 ○ The aerosol line should be kept as short Several factors determine the quantity of UFD10-1-XXX000 MQL systems have three lubricant that emerges as an aerosol at the as possible.
  • Page 70 6. Assembly ○ The aerosol lines should be routed so ○ If it is impossible to route the aerosol son to full spray lubrication, the point that they are subject to few vibrations. lines without any downward bends, the between the tool and the workpiece is accumulated lubricant must be blown out inadequately lubricated.
  • Page 71 6. Assembly Please contact SKF Service if you have ad- IMPORTANT NOTE IMPORTANT NOTE ditional questions concerning setup/instal- Only rotary leadthroughs that are suit- Check valves in rotary leadthroughs and lation of the MQL system; see the "Service" able for dry running may be used. The spindles must be removed because they chapter, p.

  • Page 72: Connection Of Aerosol Lines To An Mql System With Bypass Control

    (8) filling reservoir. As this is system-dependent, • Connect the inlet side of the bypass valve consultation with the SKF dealer or the SKF • Install the supplied Y-distributor at (6) to the aerosol line (5) coming from Customer Service department is required.
  • Page 73 6. Assembly Connecting the bypass system, Fig. 34 (3) Y-distributor (1) Aerosol line (4) Aerosol line (2) Aerosol generator (5) Aerosol line Compressed (6) Bypass valve air supply Ball valve Bypass Internal control control unit unit (8) Tool spindle (9) Bypass restrictor Tool (7) Aerosol return line Machine...

  • Page 74: Connection Of Aerosol Lines To An Optional Skf Aerosol Monitor (Am1000)

    6. Assembly 6.7.3 Connection of aerosol lines to an optional SKF aerosol monitor (AM1000) See Figure 35 Connecting the optional aerosol monitor, Fig. 35 IMPORTANT NOTE Consult the operating instructions (1) Aerosol line (2) Aerosol generator for the SKF aerosol monitor, doc. No.

  • Page 75: Electrical Connection

    6. Assembly 6.8 Electrical connection CAUTION IMPORTANT NOTE The electrical connection of the MQL On the MQL system’s electrical connections, system may only be established ensure that appropriate measures pre- by qualified and trained technical vent interference between signals due to personnel.

  • Page 76: Connector Pin Assignment On Standard Designs

    6. Assembly 6.8.1 Connector pin assignment on standard designs See Figures 36 to 45 Figure 36 shows the electric connections Electrical plug connections, Fig. 36 arranged at the base of the control cabinet housing. Bypass Valve Ball Valve Figures 37 to 45 with associated legends show the individual connection sockets/ Power RS232...
  • Page 77 UFZ.0255 DP ieldbus, M12x1 plug ieldbus coupler SKF data connection For interconnection of multiple control units; Al- SKF data connection cable UFZ.0260 M12x1 socket lows control of multiple MQL systems via a single PROFIBUS connection. SKF data connection For interconnection of multiple control units; Al- SKF data connection cable UFZ.0260...

  • Page 78: Customer Connectivity For 6.8.2 Ufd10-1-1Xx000 With Profibus

    6. Assembly 6.8.2 Customer connectivity for UFD10-1-1XX000 with PROFIBUS The contact assignments are valid only when used together with an SKF accessory cable. Additional valve and ball valve, Fieldbus coupler for PROFIBUS connection, Operating voltage connection, (Fig 36, items 6/7), Fig. 38 (Fig.

  • Page 79: Ufd10-1-2Xx000 With Profinet

    6. Assembly 6.8.3 Customer connectivity for UFD10-1-2XX000 with PROFINET The contact assignments are valid only when used together with an SKF accessory cable. PROFINET connection, Additional valve and ball valve, Operating voltage connection, Fig. 42 (Fig 36, items 6/7), Fig. 41 (Fig.

  • Page 80: Ufd10-1-20000 / Ufd10-1-201000

    6. Assembly 6.8.4 Customer connectivity for UFD10-1-20000 / UFD10-1-201000 The contact assignments are valid only when used together with an SKF accessory cable. PROFINET connection, without/with filling pump, Fig. 43 Assignment of PROFINET Power Pro net D-coded socket contact Bypass Valve...

  • Page 81: Ufd10-1-110000 / Ufd10-1-111000

    6. Assembly 6.8.5 Customer connectivity for UFD10-1-110000 / UFD10-1-111000 PROFIBUS connection, without/with bypass control, Fig. 44 1 Assignment of bypass control Bypass Valve Ball Valve A-coded socket contact (on device), Power RS232 24VDC M12x1, 5-pin 1S02 1S01 Bypass Power Valve 24VDC 2 Assignment of power supply Aerosol...

  • Page 82: Ufd10-1-210000 / Ufd10-1-211000

    6. Assembly 6.8.6 Customer connectivity for UFD10-1-210000 / UFD10-1-211000 PROFINET connection, without/with bypass control, Fig. 45 1 Assignment of PROFINET D-coded socket contact Bypass Valve Ball Valve (on device), Power RS232 24VDC M12x1, 5-pin 1S02 1S01 PROFINET Bypass Power 2 Assignment of bypass control Valve 24VDC Aerosol...

  • Page 83: Customer Connectivity With An Optional Skf Aerosol Monitor (Am1000)

    6. Assembly 6.8.7 Customer connectivity with an optional SKF aerosol monitor (AM1000) DigitalSuper UFD20 with AM1000, electrical wiring, Fig. 46 UFD10-1-XXX000 / UFD20-1-101000 UFD10-1-XXX000 / UFD20-1-101000 PARAMETER PARAMETER PARAMETER System 1 System 1 System 2 Bus cable Bus cable To connect an aerosol monitor to the MQL system, consult the operating instructions for the AM1000 aerosol monitor (951-180-071-EN).

  • Page 84: Pneumatic Connection

    6. Assembly 6.9 Pneumatic connection See Figure 47 Main compressed air valve, Fig. 47 IMPORTANT NOTE CAUTION Ensure that the compressed air connection System pressure on the main air valve is closed before con- The MQL system may only be oper- necting the MQL system to the compressed ated with a max.

  • Page 85: Setup And Fieldbus Configuration On Mql System

    7. Setup and fieldbus configuration on MQL system 7. Setup and ieldbus coniguration on MQL system 7.1 Adjustment elements See Figure 48 and Table 6 Controls, Fig. 48 On delivery, MQL systems are already con- • Remove screws (3x) from the acrylic glass figured with typical settings so that only pane using a hexagon socket screw key a few configuration steps are required to...

  • Page 86: Setting Options Via Dip Switches

    7. Setup and fieldbus configuration on MQL system 7.1.1 Setting options via DIP switches Setting options for DIP switches, Table 7 DIP switch Function Setting AM1000 aerosol monitor DIP 8 Present (connected) Not present (not connected) Process image DIP 7 With analog value transmission 5 6 7 8 Without analog value transmission...
  • Page 87 7. Setup and fieldbus configuration on MQL system 7.1.1.1 Controlling an additional valve 7.1.1.2 Controlling a reill device (DIP switch 1) (DIP switch 2 and DIP switch 3) See Table 7 See Table 7 DIP2/3 = OFF/ON The external additional valve can be con- Model designs UFDX0-1-XX1000 have a Operating mode 2: Automatic start of refill trolled directly by the control unit of the...
  • Page 88 See Table 7 The refill pump is started when the level in the aerosol generator drops below the The SKF communication connection is en- DIP switch 7 sets the process image for data “minimum” level. The refill pump is then abled using DIP switch 4.
  • Page 89 7. Setup and fieldbus configuration on MQL system 7.1.1.6 Using an aerosol monitor (DIP switch 8) See Figure 49 and Table 7 DigitalSuper UFD20 with AM1000, electrical wiring DIP switch 8 defines that the MQL system is and settings of DIP and rotary switches, Fig. 49 operated with an AM1000 aerosol monitor.
  • Page 90 7. Setup and fieldbus configuration on MQL system Setting options for DIP switches, Table 8 Control unit 1 Control unit 2 MQL design DIP switch Hex switch DIP switch Hex switch UFD10-1-100000 Not present Not present 5 6 7 8 UFD10-1-110000 Not present Not present...

  • Page 91: Fieldbus Configuration

    7. Setup and fieldbus configuration on MQL system 7.1.2 Fieldbus coniguration 7.1.2.1 Systems with PROFIBUS See Figure 50 See Figure 51 Systems in the DigitalSuper series are All MQL designs with a PROFIBUS interface If the MQL system is the last node on the equipped with a fieldbus interface.

  • Page 92: Factory Settings

    7. Setup and fieldbus configuration on MQL system 7.1.2.2 Systems with PROFINET PROFIBUS fieldbus coupler and Legend to Fig. 51 termination resistor, Fig. 51 The MQL system designs 1 M12x1 connection to MQL system UFD10-1-2XX000 have a gateway that al- 2 M12x1 connection for lows for integration of the MQL systems into termination resistor...
  • Page 93 7. Setup and fieldbus configuration on MQL system Factory settings of DigitalSuper systems, Table 9 Control unit 1 Control unit 2 MQL design DIP switch Hex switch DIP switch Hex switch UFD10-1-100000 Not present Not present 5 6 7 8 UFD10-1-110000 Not present Not present...

  • Page 94: Communication With Machine Control Unit

    10X000 have a PROFIBUS interface, and can be downloaded from: UFD20-1-10X000 are integrated into the design UFD10-1-2XX000 has a PROFINET www.skf.com/digitalsuper PROFIBUS network via a model PDP22 interface. fieldbus plug (FBP). FieldBusPlug is a mod- ular I/O slave on the PROFIBUS with one On both fieldbus systems, communication is slot that is occupied by the MQL system.

  • Page 95: Implementation In A Profinet Network

    8. Communication with machine control unit o If you select the process image with Factory settings of DigitalSuper systems, Table 10 analog value transmission (UFD10A or Object MQL design UFD20A), DIP switch 7 on the respective UFD10 UFD10A UFD20 UFD20A control unit must be set to ON (see Chap- UFD10-1-100000 ter 7.1.1).

  • Page 96: Process Image Of Mql Systems

    8. Communication with machine control unit To do this, import the corresponding GSDML The machine tool’s control unit receives dis- file into the customer’s Field Device Tool and o If the AM1000 is used, DIP switches 4, 7, crete information on the current state of the integrated it into the customer’s network and 8 in the MQL control unit must be set MQL system via the two input bytes.

  • Page 97: Assignment Of Input Bytes (Input Byte 0 And Input Byte 1) - Data From Mql System To Machine

    8. Communication with machine control unit 8.2.1 Assignment of input bytes (input byte 0 and input byte 1) - data from MQL system to machine Assignment of input bytes (input byte 0/input byte 1), Table 11 Input bytes Function Setting Bit assignment Input byte 0 7 6 5 4 3 2 1 0...
  • Page 98 8. Communication with machine control unit 8.2.1.1 Information on oil level 8.2.1.2 Information on lubricant low 8.2.1.3 Information on inlet pressure (input byte 0, bits 0-3) (input byte 0, bit 4) (input byte 0, bit 5) The MQL systems can hold a lubricant sup- During operation, a flow sensor monitors The pressure sensor measures the inlet ply of approx.
  • Page 99 8. Communication with machine control unit 8.2.1.4 Information on pressure differ- 8.2.1.5 Information on system status 8.2.1.6 Information on the reill device ential (input byte 0, bit 6) (input byte 0, bit 7) (input byte 1, bit 0) A pressure sensors monitors the air pres- Bit 7 in input byte 0 provides information on Bit 0 in input byte 1 is relevant for MQL sys- sure in the aerosol generator on the MQL...

  • Page 100: Assignment Of Input Words

    8. Communication with machine control unit 8.2.1.7 Information on data exchange with an aerosol monitor ○ In output byte 0, bit 0 is briefly set to (input byte 1, bit 1) By default, MQL system designs <<1>> (Chapter 8.2.3.2) UFD10-1-2XX000 provide the input words Bit 1 in input byte 1 indicates whether there via the GSDML file.
  • Page 101 8. Communication with machine control unit Input word assignments when using a process image with analog value transmission, Table 12 Input words Value/signal Value range Unit Explanation Word 4 3 2 1 0 Rela- tive 12 10 8 6 4 2 0 address Relative value, transmitted from aerosol monitor to Aerosol density...

  • Page 102: Assignment Of Output Bytes (Output Byte 0 And Output Byte 1) - Data From Machine To Mql System

    8. Communication with machine control unit 8.2.3 Assignment of output bytes (output byte 0 and output byte 1) - data from machine to MQL system Assignment of output bytes (output byte 0/output byte 1), Table 13 Output bytes Function Setting Output byte 0 7 6 5 4 3 2 1 0 Filling pump...
  • Page 103 8. Communication with machine control unit 8.2.3.1 Controlling a reill device (output 8.2.3.2 Resetting a timeout error (output 8.2.3.3 Switching the main air valve byte 0, bit 0) byte 0, bit 1) (output byte 0, bit 5) MQL systems with integrated refill pump A timeout error caused by exceeding the The main air valve can be opened and (UFDX0-1-XX100) can be configured so...
  • Page 104 8. Communication with machine control unit 8.2.3.4 Switching an external additional 8.2.3.5 Switching an external ball valve 8.2.3.6 Calling the lubrication programs valve (output byte 0, bit 6) (output byte 0, bit 7) (output byte 1, bits 0-5) An additional valve can be controlled via A ball valve can be controlled via output 7 on Lubrication programs are called using bits 0 output 6 on the MQL control unit.
  • Page 105 8. Communication with machine control unit Lubrication programs, Table 14, (1 of 2) Program Output byte 1 Air volume Lubricant volume Cooling duct diameter flow flow ) [ml/h] of tool [mm] 1 duct 2 ducts 100% Automatic 2x0.7 control 1x1.5 2x1.1 2x1.4 1x2.5...
  • Page 106 2x0.4 to 0.7 The lubricant flow volumes indicated here are guiding values only. They relate to oil type “SKF LubriOil” at a primary pressure of 6 bar with a tolerance of ± 20%. The measurements were conducted according to SKF Measuring Instructions No. 245-940.00.

  • Page 107: Commissioning/Operation

    Only lubricants provided by SKF is filled. pling (1) downwards may be used. SKF will not accept claims for damages resulting from the use of lubricants other • Moving the slider (2) on the main com- CAUTION than those approved in writing by SKF.

  • Page 108: Manual Filling

    9. Commissioning/Operation 9.2 Manual illing 9.3 Automatic illing See Figure 52 MQL systems can optionally be filled auto- matically. IMPORTANT NOTE IMPORTANT NOTE This requires that the customer’s supply line Only fill using clean lubricant and an ap- Close the fillport tightly after filling. Ensure be connected to the port on the filling pump propriate device.

  • Page 109: Commissioning

    9. Commissioning/Operation 9.4 Commissioning Filling, Fig. 52 The following are to be performed during This can be seen best if the tool is re- commissioning: moved from the toolholder. The aerosol must emerge visibly from the cooling • Check the control cabinet housing and all duct system.

  • Page 110: Operation

    9. Commissioning/Operation 9.5 Operation 9.6 Reilling lubricant SKF products operate largely automatically. See Chapter 11.2 for a description. IMPORTANT NOTE The activities required during normal op- If the MQL system is adjusted improperly, eration are limited primarily to inspection tools or and/or the workpiece may be of the fill level, timely refilling of lubricant, damaged.

  • Page 111: Cleaning

    The interior of the product must be cleaned • Thoroughly clean all external surfaces if incorrect or contaminated lubricant is ac- cidentally filled. with a moist cloth. The refilling reservoir must be Please contact SKF Customer Service. kept closed during cleaning. - 111 - 951-170-218-EN Version 06...

  • Page 112: Cleaning The Fine Filter For Compressed Air

    10. Cleaning 10.4 Cleaning the ine ilter for com- pressed air See Figure 53 The aerosol lines (1) and the aerosol CAUTION generator (2) must be purged. Each aerosol generator in the MQL system is equipped with a fine filter for compressed •...

  • Page 113: Cleaning The Oil Filter

    10. Cleaning 10.5 Cleaning the oil ilter See Figure 53 Cleaning the filter for compressed air and Note • Remove the strainer insert (9) and clean the oil filter, Fig. 53 The oil filter should be checked and with suitable, permitted cleaning agents if necessary cleaned at least 1x per or replace it.

  • Page 114: Maintenance

    CAUTION CAUTION IMPORTANT NOTE Electric shock System pressure Only original SKF spare parts may be used. Supply voltage must be switched Aerosol reservoirs on Unauthorized alterations and the use of off before opening any of the MQL MQL systems are pressurized non-original spare parts and accessories system’s components.

  • Page 115: Refilling Lubricant In Systems With Manual Lubricant Refill

    Check whether the pressure has been completely released by briely actuating the Internet at: The refilling reservoir must be the safety valve (5). www.skf.com/lubrication depressurized before refilling with lubricant. CAUTION • Activate lubrication program No. 3 Wear safety goggles and a facial (Chapter 8.2.3.6).
  • Page 116 • Fasten the filler screw finger-tight us- the iller screw (6). It must be rein- permission from SKF. This can lead to ing a hexagon socket screw key. stalled after illing is complete. damages and would require extensive in- ternal cleaning of the system.

  • Page 117: Draining Lubricant

    11. Maintenance 11.3 Draining lubricant See Figure 54 CAUTION Main compressed air valve, Fig. 54 System pressure The refilling reservoir must be depressurized before refilling with Aerosol outlets (4) lubricant. Aerosol generator (1) Safety valve (5) Filler screw (6) Observe the regulations for disposal 1500 1400 1300...
  • Page 118 11. Maintenance • Wait until the pressure has been re- To drain the lubricant, connect an oil- On MQL systems with an automatic refill leased via the aerosol outlets (4). resistant hose to the lubricant drain device: valve (7) (on the underside of the control cabinet housing).

  • Page 119: Malfunctions, Causes, And Remedies

    IMPORTANT NOTE that the MQL system Table 16 shows possible error messages Only original SKF spare parts may be used. functions smoothly: from the control unit’s LED display that Unauthorized alterations to products and relate to communication via the SKF data the use of non-original spare parts and ac- o The system is correctly connected.

  • Page 120: Malfunctions And Their Resolution

    Cause Remedy o Use of lubricants not approved by SKF • Use only lubricants which have been approved by SKF. The system o The system is not activated correctly by the machine tool’s • Check the connection plug and the signal cable. If this does not help,...
  • Page 121 Cutting parameters are not adapted to machining using • Change the cutting parameters. minimal quantity lubrication. The flow sensor display o Flow sensor is defective or misadjusted. • Contact SKF’s service department. is faulty. - 121 - 951-170-218-EN Version 06...

  • Page 122: Error With The Use Of Mql Systems With Bypass Control

    Incorrect program number configured • Use program number 50 Bypass valve does not cycle during machining process o Unsuitable ratio between cooling duct diameter and by- • Record operating parameters and contact SKF Service pass restrictor diameter - 122 - 951-170-218-EN Version 06...

  • Page 123: Error Notifications Via Led Display

    12. Malfunctions, causes, and remedies 12.4 Error notiications via LED display Error notifications and remedy, Table 17 (1 of 2) Malfunction Cause Remedy This message can appear with units of the UFD20 type when 1. Check the data connection between the two con- the MQL control unit with bus address 00 is not able to establish trol units of the UFD20.
  • Page 124 12. Malfunctions, causes, and remedies Error notifications and remedy, Table 17 (2 of 2) Malfunction Cause Remedy 1. Check the data line to the aerosol monitor This message appears with the UFD20 when DIP switch 8 is “ON,” 2. Check the settings of DIP switch 2 in the aerosol E060 configuring an aerosol monitor as present in the right-hand control monitor.

  • Page 125: Replacing Defective Fuses

    12. Malfunctions, causes, and remedies 12.5 Replacing defective fuses See Figure 55 Fuses, Fig. 55 The following fuses are mounted in the MQL UFD10-1-X1X000 control cabinets. UFD10-1-X1X000 Power supply and fuses for this MQL sys- tem are mounted in the PROFINET control cabinet.

  • Page 126: Shutdown, Disposal

    13. Shutdown, disposal. Shutdown, disposal 13.1 Temporary shutdown 13.3 Permanent shutdown, disassembly The producer of waste is respon- Temporary shutdown is performed by: Permanent shutdown and disassembly of sible for its specific classification, the product must be planned properly by the as the European Waste Catalog ○...

  • Page 127: Spare Parts

    14.Spare parts Spare parts Spare parts, Table 18 Item Quantity Order No. Designation 1.000 pcs. UFD.U41-000 Control unit, complete 1.000 pcs. UFD.U11-004 Reservoir, complete 1.000 pcs. UFD.U20-007 Control unit, complete 1.000 pcs. FLM12-S58+924 FLP unit, 24 VDC 1.000 pcs. UFD.U50-002 Cable harness, complete 1.000 pcs.

  • Page 128: Accessories

    15. Accessories Accessories Accessories, Table 19 Designation Order No. Ball valve 2/2-way 100 bar UFZ.U00-128 Ball valve 3/2-way 100 bar for aerosol / cooling lubricant switching UFZ.U00-041 Aerosol hose ø 12 mm running meter UFZ.0027 Aerosol nozzle, complete Incl. nozzle with connection G 1/8 A, plastic articulated tube (17 cm), magnetic holder UFZ.U00-062 for external lubrication Aerosol nozzle connection G 1/8...
  • Page 129 15. Accessories Accessories, Table 20 Designation Order No. Minimal quantity lubricating oils 2.5 l canister OEL2.5-LUBRIOIL 5.0 l canister OEL5-LUBRIOIL LubriOil - Ester High lubricating effect 10 l canister OEL10-LUBRIOIL 2.5 l canister OEL2.5-LUBRI-F100 Especially for aluminum machining 5.0 l canister OEI5-LUBRI-F100 LubriFluid F100 - Fatty alcohol Low lubricant residues...
  • Page 130 The Power of Knowledge Engineering Bearings Over the course of more than a century, SKF has specialized in five fields of competence and acquired a Lubrication Seals and Bearing wide range of application expertise. We utilize this experience to provide innovative solutions to OEMs...

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