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Assembly instructions Lubricant pump P203 following machinery directive 2006/42/EC for multi-line lubrication systems AC versions without PCB LINCOLN LINCOLN LINCOLN LINCOLN LINCOLN 951-171-020-EN Version 01 28/03/2018 P203 AC wo PCB 951-171-020-EN-V01.indd 1 09.01.2019 10:56:00...
EC Declaration of incorporation EC Declaration of incorporation acc. to machinery directive 2006/42/EC The manufacturer, SKF Lubrication Systems Germany GmbH, Walldorf Facilities, Heinrich-Hertz-Str. 2-8, DE - 69190 Walldorf, hereby declares that the partly completed machinery Designation: Electrically driven pump to supply lubricant during intermittent operation within a centralized lubrication system...
○ Intent or negligence Warranty Berlin Facilities The instructions do not contain any informa- ○ use of non-original SKF spare parts Motzener Straße 35/37 tion on the warranty. This can be found in ○ Faulty planning or layout of the central- 12277 Berlin our general terms and conditions.
Table of contents Table of contents EC Declaration of incorporation acc. to machinery directive 2006/42/EC ..2 Legal disclosure ...................... 3 Explanation of symbols, signs and abbreviations ..........7 Safety instructions .................9 Lubricants ................... 17 General safety instructions ..............9 General information ................17 General behaviour when handling the product ........
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Table of contents Useable reservoir volume ..............32 Filling with lubricant ................52 4.10 Lubricant requirement for priming of an empty pump ....33 6.8.1 Filling via the reservoir lid ..............52 4.11 Tightening torques ................34 6.8.2 Filling via filler fitting ................53 4.12 Type identification code ................35 6.8.3 Filling via the optional filling connection ..........54 Delivery, returns, and storage ............
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Table of contents Repairs ..................61 14.7 Adapter with lubrication fitting ............65 12.1 Check pump element and replace pressure control valve....61 14.8 Closure screw M22 x 1,5..............65 14.9 Transparent reservoir ................66 Shutdown and disposal ............... 62 14.10 Fixed paddle ..................67 13.1 Temporary shutdown ................62 14.11...
Explanation of symbols, signs and abbreviations Explanation of symbols, signs and abbreviations The following abbreviations may be used within these instructions. Symbols within safety notes mark the kind and source of the hazard. General warning Dangerous electrical voltage Risk of falling Hot surfaces Unintentional intake Crushing hazard...
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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 poss. possibly hour inch if appl. if applicable second pounds per square inch incl.
1. Safety instructions 1. Safety instructions 1.1 General safety instructions 1.2 General behaviour when handling the product ○ The owner must ensure that safety infor- ○ Responsibilities for different activities ○ The product may be used only in aware- mation has been read by any persons en- trusted with works on the product or by ness of the potential dangers, in proper must be clearly defined and observed.
1. Safety instructions 1.3 Intended use 1.6 Prohibition of certain activities ○ to supply, transport, or store hazardous Supply of lubricants within a centralized lu- Due to potential sources of faults that may substances and mixtures in accordance brication system following the specifications, not be visible or due to legal regulations with annex I part 2-5 of the CLP regula- technical data and limits stated in these...
1. Safety instructions 1.8 Notes related to the CE marking 1.9 Inspections prior to delivery CE marking is effected following the require- The following inspections were carried out ments of the applied directives: prior to delivery: ○ 2014/30/EU ○ Safety and functional tests Electromagnetic compatibility ○...
1. Safety instructions 1.12 Notes related to the type identiica- 1.11 Markings on the product SKF Lubrication Systems Germany GmbH tion plate Model: P203-xxxxx-xxx-xx P. No.: 644-xxxxx-x S. No.: xxxxxxxxxxxx The type identification plate states important characteristics such as type designation, or-...
1. Safety instructions 1.14 Brieing of external technicians 1.13 Persons authorized to operate the 1.16 Operation pump The following must be observed during com- Prior to commencing the activities, external missioning and operation: technicians must be informed by the opera- 1.13.1 Operator tor of the company safety provisions, the ○...
1. Safety instructions 1.18 Transport, installation, maintenance, ○ Ensure through suitable measures that ○ Carry out electrical connections only ac- malfunctions, repair, shutdown, movable or detached parts are immobi- cording to the information in the valid disposal lized during the work and that no limbs wiring diagram and taking the relevant ○...
1. Safety instructions 1.19 Initial commissioning / daily start-up 1.20 Cleaning ○ Risk of fire and explosion when using ○ All components used must be designed Ensure that: inflammable cleaning agents Only use ○ All safety devices are completely available according to the maximum operating non-flammable cleaning agents suitable pressure and the maximum respectively...
1. Safety instructions 1.21 Residual risks Residual risk Possible in life cycle Prevention/ remedy Personal injury/ material damage due to Keep unauthorized persons away No people may remain under suspended loads. Lift A B C G H K falling of raised parts parts with adequate lifting devices.
2.2 Selection of lubricants 2.3 Material compatibility Lubricants are used specifically for cer- SKF considers lubricants to be an element Lubricants must generally be compatible tain application purposes. In order to fulfil of system design. A suitable lubricant is se-...
(e.g. "bleeding"). hazard designations, if any, on the packaging have to be Please contact SKF. if you have further ques- observed. tions regarding lubricants. You may request an overview of the lubri- cants tested by SKF.
NOTICE Chisel pastes containing calcium carbonate Solid lubricants may be used only are likely to cause a very strong wear on pis- upon prior consultation of SKF Damage to the superior machine tons, bores and mating surfaces. Lubrications Systems. Chisel pastes must not be used as a lubri- Calcium hydroxide cant for bearings.
3. Overview, functional description 3. Overview, functional description Overview, functional description of pumps without follower plate Fig. 1 3.1 Pumps without follower plate 1 Reservoir The lubricant is stored in the reservoir. De- pending on the pump version there are differ- ent types of reservoirs and reservoir sizes.
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3. Overview, functional description Overview, functional description of pumps without follower plate Fig. 2 2 Pump housing The pump housing accommodates the motor, Type of connection the electrical connections, the filler fitting and the pump elements. Square plug 3 pump elements The pump can be equipped with up to 3 pump elements (see chapter 4.9).
3. Overview, functional description Overview, functional description of pumps with follower plate Fig. 3 3.2 Pumps with follower plate 1 Reservoir The lubricant is stored in the reservoir. De- pending on the pump version there are differ- ent types of reservoirs and reservoir sizes. 1.2 Reservoir venting device It provides air for the reservoir while the pump is operating and lubricant is supplied.
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3. Overview, functional description Overview, functional description of pumps with follower plate Fig. 4 2 Pump housing The pump housing accommodates the motor, Type of connection the electrical connections, the filler fitting and the pump elements. Square plug 3 pump elements The pump can be equipped with up to 3 pump elements.
4. Technical data 4. Technical data 4.1 General technical data Operating pressure max. 350 bar [5076 psi] Rated voltage 110 - 260 V AC (± 10 %) Number of pump elements max. 3 Frequency 50-60 Hz (± 5 %) | 1-phase Direction of rotation clockwise Recommended back-up fuse...
4. Technical data 4.2 Protection type and class 4.3 Hydraulic connection diagram 1 = Reservoir Degree of protection IP6K9K Protection classes 2 = Pump Connection nominal voltage Protection class 1 3 = Check valve Connection signal line Protection class 3 4 = Pressure control valve - Square plug SELV / PELV / FELV...
4. Technical data 4.4 Nominal output volumes The stated nominal outputs per stroke and pump element refer to NLGI 2 lubrication greases at an ambient temperature of + 20 °C [68 °F] and a back pressure of 100 bar [1450 psi] on the pump element. Deviating operating conditions or deviating pump configuration result in a changed motor speed and thus in a change of the output per time unit.
4. Technical data 4.4.2 Output diagrams of typical NLGI 2 lubricants Low temperature lubrication grease High temperature lubrication grease °C °C 86 104 122 °F 86 104 122 °F The output diagrams represent the average value of the different high- respectively low-temperature lubrication greases. Calculation of the output using the example of a high-temperature lubrication grease Nominal speed of the pump motor per minute x nominal output of pump element 7 per stroke x efficiency in percent at an assumed ambient temperature of -10 °C [14 °F] = 20 rpm x 0.22 cc (0.0134) x 80 % = 3.5 cc/min [0.214 cu.in./min.].
4. Technical data 4.5 Functioning principle of the intermittent low-level indication The intermittent low-level indication operates free of contact. Its main components are the following: ○ firmly positioned magnetic switch (I) inside of the reservoir bottom ○ flexible guide plate (II) connected to the stirring paddle with a magnet (III) and a control cam (IV) If the reservoir is filled with a lubrication grease suitable for the intermittent low-level indication and the pump is operating, then the guide plate (II) is de- flected by the resistance of the lubrication grease.
4. Technical data 4.6 Limits of use of the intermittent low-level indication The following lubricant consistencies have to be complied with in order to ensure the correct functioning of the intermittent low-level indication. Above the stated range of temperature a correct functioning of the intermittent low-level indication cannot be ensured. The inferior temperature ranges require the suitability of the lubricant for the respective temperature range.
4. Technical data 4.7 Processing of the low-level signals in case of external controller and monitoring of the pump The following statements apply to pumps with control printed circuit board type V and for pumps without printed circuit board with external controller and monitoring.
4. Technical data 4.8 Reservoir versions In the following you find the possible reservoir variants of the pumps described in these instructions (also see type identification code). For a better representation only the smallest possible reservoir size will be depicted always. In the figures the different reservoir variants may not ü...
4. Technical data 4.9 Useable reservoir volume Regarding the reservoir version without follower plate the useable reservoir volume mainly depends on the NLGI consistency class of the lubricant to be used and of the ambient temperature. In case of high consistency and low operating temperature normally more lubricant sticks to the inner surfaces of the reservoir and the pump and is thus no more available for being dispensed.
4. Technical data 4.10 Lubricant requirement for priming of an empty pump To prime an empty pump up to the MAX marking of the reservoir, the following lubricant quantities are required. Nominal volume | Litres / [gal.] 2 [0.53] 4 [1.06] 8 [2.11] 11 [2.90] 15 [3.96]...
4. Technical data 4.12 Type identiication code The type identification code facilitates selection/ identification of important features of the product. For the type identification code of the respective prod- uct, see the type identification plate on the pump. P 2 0 3 X U - 1 1 X L B 0 - 6 0 0 - A C - D 1 0 0 G 2 0 0 - _ _ _ A + _ _ _ Example H K H K H K H K Category 1 2 3...
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4. Technical data P 2 0 3 X D - 1 1 X L B 0 - 6 0 0 - A C - D 1 0 0 G 2 0 0 - _ _ _ A + _ _ _ Example H K H K H K H K Category 1 2 3...
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4. Technical data P 2 0 3 X D - 1 1 X L B 0 - 6 0 0 - A C - D 1 0 0 G 2 0 0 - _ _ _ A + _ _ _ Example H K H K H K H K Category 1 2 3...
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4. Technical data P 2 0 3 X D - 1 1 X L B 0 - 6 0 0 - A C - D 1 0 0 G 2 0 0 - _ _ _ A + _ _ _ Example H K H K H K H K Category 1 2 3...
5.3 Storage 5.4 Storage temperature range ○ In case of parts not filled with lubricant After receipt of the shipment, check the SKF products are subject to the following shipment for damage and completeness storage conditions: the admissible storage temperature according to the shipping documents.
5. Delivery, returns, and storage 5.5 Storage conditions for parts illed 5.5.3 Storage period exceeding 18 Metering devices with lubricant months • Remove all connection lines and closure To avoid dysfunctions consult the manufac- The conditions mentioned in the follow- screws, if any turer before commissioning.
6. Installation 6. Installation 6.2 Place of installation 6.1 General information ○ Possibly existing visual monitoring de- Protect the product against humidity, dust Only qualified technical personnel may install vices, e.g. pressure gauges, MIN/MAX and vibrations and install it in an easily ac- the products described in these Instructions.
6. Installation 6.3 Mechanical connection 6.3.1 Minimum assembly dimensions Ensure sufficient space for maintenance work or for attachment of further components to build a centralized lubrication system to the pump by leaving a free space of at least 100 mm [3.94 in.] into each direction in addition to the stated dimensions. Reservoir Reservoir size Reservoir size...
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6. Installation Minimum assembly dimensions Fig. 5 LINCOLN LINCOLN LINCOLN LINCOLN LINCOLN 951-171-020 - 44 - Version 01 P203 AC wo PCB 951-171-020-EN-V01.indd 44 09.01.2019 10:56:14...
6. Installation 6.3.2 Installation bores Pumps with 8 l [2.11 gal.] reservoir Pumps with 2 l [0.53gal.] or 4 l [1.06 gal.] reservoir Are fixed at the three lower fastening points NOTICE (A) or (B) and (C) of the pump housing. Are fixed at the two lower fastening points (A) or (B) of the pump housing.
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6. Installation Pumps with 11 l [2.9 gal.] or 15 l [3.96 gal.] Mounting bores for pumps with 11 l [2.9 gal.] or 15 l [3.96 gal.] reservoir Fig. 7 reservoir Are fixed on the lower mounting bores (A) or (B) of the pump housing and additionally on the 2 upper mounting points (D).
6. Installation 6.4 Electrical connection Electrical connection, Fig. 8 Type of connection WARNING Square plug Electric shock Make sure to disconnect the product from the power supply before carrying out any works on electrical components. Carry out the electrical connection accor- ding to the connection type of the pump, •...
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6. Installation Electrical connection of the low-level indication of pumps with follower plate Fig. 9 The electrical connection of the low-level indication (5.3) of pumps with follower plate is made according to the pump’s connection type. See chapter Connection of the signal line to the reservoir lid 951-171-020 - 48 - Version 01...
6. Installation 6.5 Adjusting the output volume on the Adjusting the output volume on pump element R Fig. 10 pump element R The output of pump element [0.0061] 0,18 R can be adjusted only while the pump is idle. Factory [0.0054] 0,16 setting is full supply, i.e.
6. Installation 6.6 Mount pressure control valve Mounting the pressure control valve Fig. 11 Protect each pump element by means of a pressure control valve suitable for the planned maximum admissible operating pressure of the centralized lubrication system. Observe the information given in chapter 4 regarding the adapter required for certain reservoir sizes.
6. Installation 6.7 Lubrication line connection ○ The lubricant flow should not be impeded Observe the following installation instruc- CAUTION by the installation of sharp elbows, angle tions for safe and smooth operation. valves, gaskets protruding to the inside, ○ Use clean components and filled lubrica- Risk of falling or cross-section changes (big to small).
6. Installation Filling via the reservoir lid Fig. 12 6.8 Filling with lubricant 6.8.1 Filling via the reservoir lid WARNING Crushing hazard on the rotating stirring paddle. Fill- ing via the reservoir lid is allowed only after disconnecting the pump from the power supply by removing it from the connection (5.1).
6. Installation 6.8.2 Filling via iller itting Filling via filler fitting Fig. 13 • Connect filling connection of filler pump with filler fitting (4). • Switch on filler pump and fill reservoir until shortly below the MAX marking • Switch filler pump off and remove it from filler fitting (4) of pump 951-171-020 Version 01...
6. Installation 6.8.3 Filling via the optional illing Filling with lubricant via filling connection Fig. 14 connection • Unscrew protective cap (20.1) from fill- ing connection (20) anticlockwise • Connect filling connection of filler pump with filler fitting (20) • Switch on filler pump and fill reservoir until shortly below the MAX marking •...
7. Initial start-up 7. Initial start-up In order to warrant safety and function, a person assigned by the operator must carry out the following inspections. Immediately eliminate detected deficiencies. Deficiencies may be remedied by an authorized and qualified specialist only. Start-up check list 7.1 Inspections prior to initial start-up Electrical connection carried out correctly.
8. Operation 8. Operation SKF products operate automatically to the greatest possible extent. Basically, activities during standard opera- tion are limited to the control of the filling level of pumps without low-level indication and the timely refilling of lubricant. 8.1 Reill lubricant...
• Thorough cleaning of all outer surfaces uct will be required. Thoroughly remove residues with a damp cloth. To do so, contact the SKF Customer Service. of cleaning agents from the product and rinse off with clear Make sure to keep the reser- water.
10. Maintenance Maintenance Regular and appropriate maintenance is a prerequisite to detect and clear faults in time. The specific timelines have to be determined, verified at regular intervals and adapted, if necessary, by the operator based on the operating conditions. If needed, copy the table for regular mainte- nance activities.
11. Troubleshooting Troubleshooting Fault table 1 Fault Possible cause Remedy Pump does not run Power supply to pump interrupted Check whether one of the indicated faults is present and rem- edy it in the frame of responsibilities. - Superior machine is switched off - Connection cable of pump is loose or defective Faults outside of your own responsibility have to be reported to your superior to initiate further measures.
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11. Troubleshooting Fault table 2 Fault Possible cause Remedy Blockade, fault within the centralized lubrication system Defective check valve Defective pressure relief valve Suction bore of pump element is clogged Check whether one of the indicated faults is present and rem- edy it in the frame of responsibilities.
12. Repairs Repairs 12.1 Check pump element and replace Replace pump element Fig. 15 WARNING pressure control valve. Risk of injury The characteristics of the new Before carrying out any repair work, pump element must correspond take at least the following safety to the characteristics of the pump measures: element to be replaced.
13. Shutdown and disposal Shutdown and disposal 13.1 Temporary shutdown 13.3 Disposal Countries outside the European Union Temporarily shut the system down by: Countries within the European Union The disposal has to be done according to the ○ Switching off the superior machine. Disposal should be avoided or minimized valid national regulations and laws of the wherever possible.
14. Spare parts Spare parts The spare parts assemblies may be used exclusively for replacement of identical defective parts. Modifications with spare parts on existing products are not allowed. Exceptions to this are the pump elements and the optional filling connection. 14.1 Housing cover assy.
14. Spare parts 14.6 Magnetic switch normally open (NO) Fig. 21 Designation Qty. Part number Magnetic switch normally open (NO) for intermittent low-level indication 544-60276-1 Delivering including housing cover, drain hose, and the corresponding number of screws required for installation 14.7 Adapter with lubrication itting Fig.
14. Spare parts 14.10 Fixed paddle Fig. 25 Designation Qty. Part number Fixed paddle 4 XNBO 444-70490-1 Fixed paddle 8 XNBO 444-70491-1 14.11 Reservoir lid Fig. 26 Designation Qty. Part number A) Reservoir lid 4/8l [1.06/2.11 gal.] XNBA/XLBA 544-36963-1 B) Reservoir lid 4/8l [1.06/2.11gal.] 544-31992-1 A) Lockable including 2 keys and warning label B) Including warning label...
14. Spare parts 14.13 Connection sockets and cable Feature* Qty. Part number Designation Fig. 28 Connection socket with gasket and screw 544-32850-1 Connection socket with gasket and screw 544-33843-1 Connection cable 10 m (33 ft) with connection socket 664-36078-7 Connection cable 10 m (33 ft) with connection socket 664-36078-9 *Feature in type identification code (category K connection material) H) = black...
14. Spare parts 14.14 Replacement kit P203 AC pumps Fig. 29 Designation Qty. Part number Replacement kit of power supply board 544-60043-1 +24Vdc 0Vdc Delivering including housing cover, drain hose, and the corresponding number of screws required for installation 951-171-020 Version 01 - 69 - P203 AC wo PCB 951-171-020-EN-V01.indd 69...
15. Connection diagrams Electrical connections 15.1 Cable colours following IEC 60757 Abbreviation Colour Abbreviation Colour Abbreviation Colour Abbreviation Colour black green white pink brown yellow orange turquoise blue violet ----- ----- The assignment of the following electrical connection diagrams is done according to the respective referenced type identification code characteris- tics.
15. Connection diagrams 15.2 Connection of signal line to reservoir lid Connection of the signal with the square plug to reservoir lid Fig. 30 Connection diagram (lubrication grease) Connection diagram (lubrication grease) Connection diagram (lubricating oil) Magnetic switch Low-level indication Magnetic switch high- and low-level indication Float magnetic switch Low-level indication Depiction of unactuated condition...
15. Connection diagrams 15.3 Recommended contact protection measure for switching inductive loads Recommended contact protection measure for switching inductive loads Fig. 31 For protection of the relay contacts the following contact protection measure should be carried out by the operator. V DC 1 Magnetic switch 2 Interference suppression diode...
15. Connection diagrams 15.4 Connection diagram P203 V AC without control PCB Connection diagram P203 V AC without control PCB Fig. 32 P203 804-51098-1 Page 1/1 L1 Low-level indication High-level indication Low-level indication L3 Prewarning empty High-level indication 24V Motor 3 2 1 0 No connection D Square plug - power supply plate/supply line...
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Notes P203 AC wo PCB 951-171-020-EN-V01.indd 74 09.01.2019 10:56:30...
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SKF Lubrication Systems Germany GmbH Walldorf Facilities Heinrich-Hertz-Str. 2-8 DE - 69190 Walldorf Phone: +49 (0) 6227 33-0 Fax: +49 (0) 6227 33-259 e-mail: Lubrication-germany@skf.com www.skf.com/lubrication 951-171-020-EN Version 01 28/03/2018 P203 AC wo PCB 951-171-020-EN-V01.indd 77 09.01.2019 10:56:30...
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