Professional Documents
Culture Documents
2006/42/EC
for partly completed machinery with associated operating instructions EN
for vehicle lubrication
max
max max max
ax
in
Use hard grease NLGI-2 only !
1 1
2 2
3 3
Version 05
EN Page 2 Notes
Service
Masthead © SKF Lubrication Systems Germany GmbH
If you have technical questions, please contact
These assembly instructions with associated op- This documentation is protected by copyright. the following addresses:
erating instructions according to EC Machinery SKF Lubrication Systems Germany GmbH
Directive 2006/42/EC are an integral part of reserves all rights, including those to the SKF Lubrication Systems Germany GmbH
the described product and must be kept for fu- photomechanical reproduction, duplication,
ture use. and distribution by means of special procedures Berlin Plant
KFG KFGS KFGL KFGC
These assembly instructions with associated op- (e.g., data processing, data media, and data Motzener Straße 35/37
erating instructions have been prepared in ac- networks) of this documentation in whole or in 12277 Berlin, Germany
cordance with the established standards and part. Germany
rules for technical documentation, VDI 4500 Tel. +49 (0)30 72002-0
and EN 292. Subject to changes in contents and technical Fax +49 (0) 30 72002 111
information.
Hockenheim Plant
2. Industriestrasse 4
68766 Hockenheim
Germany
Tel. +49 (0)62 05 27-0
Fax +49 (0) 62 05 / 27-101
lubrication-germany@skf.com
www.skf.com/lubrication
Table of contents Page 3 EN
10. KFGL control unit 81 14. Operational and pump faults 95 15. Technical data 102
10.1 Display and control elements 14.1 Operational malfunctions 95
of control screen 81 14.1.1 General information 95
10.2 Display and control menu 83 14.1.2 Malfunctions on pump units 95 16. Accessories 105
10.2.1 Main menu 83 14.2 Malfunctions on KFGS pump units 97
10.2.2 Info - Information mode 84
10.2.3 Conig. - Coniguration mode 86
14.2.1 Display faults 97
14.2.2 Delete fault notiication 97
10.3 Programming a KFGL pump unit 88 14.2.3 Fault types 98
14.2.4 Recording fault times 99
The manufacturer SKF Lubrication Systems Germany GmbH ,Plaint Hockenheim, 2. Industriestraße 4, DE - 68766 Hockenheim hereby declares that
the partly completed machinery:
Designation: Piston pump aggregate for vehicle lubrication
Type: KFG, KFGS, KFGL, KFGC
Part no.: KFG*; KFG*F*; 772-*
Year of construction: See type identification plate
complies with the following basic requirements of the EC Machinery Directive 2006/42/EC at the time when first being launched in the market.
1.1.2 · 1.1.3 · 1.3.2 · 1.3.4 · 1.5.1 · 1.5.6· 1.5.8 · 1.5.9 · 1.6.1 · 1.7.1 · 1.7.3 · 1.7.4
The special technical documents were prepared following annex II part B of this directive. Upon justifiable request, these special technical documents can be forwarded
electronically to the respective national authorities. The person empowered to assemble the technical documentation on behalf of the manufacturer is the head of
KFG KFGS KFGL KFGC
Hockenheim, 2016/04/25
Description/ The operator of the described prod- In addition to the assembly instructions,
Document number uct must ensure that the assembly general statutory regulations and other
instructions are read and understood by regulations for accident prevention
LC502 control unit for ProFlex all persons tasked with the assembly, and environmental protection must be
progressive centralized lubrication systems operation, maintenance, and repair of observed and applied.
951-180-005-EN the product. The assembly instructions
must be kept readily available.
LC502 control unit for MonoFlex
KFG KFGS KFGL KFGC
Pump units of SKF's KFG, KFGS, KFGL and maximum permissible temperature. Only qualified technical personnel may install,
KFGC series are used to supply centralized lu- operate, maintain, and repair the products de-
brication systems in vehicles, systems and ma- Unless specially indicated otherwise, products scribed in the assembly instructions. Qualified
chines. They deliver oils and greases (up to from SKF Lubrication Systems Germany GmbH technical personnel are persons who have
NLGI Grade 2). are not approved for use in potentially explosive been trained, assigned and instructed by the
The use of synthetic oils requires prior approval areas as defined in the ATEX Directive operator of the final product into which the de-
Electrical connections for the described product Dangerous contact voltages may occur The described product is pressurized
may only be established by qualified and on the unit if the protective earth during operation. The product must
trained personnel authorized to do so by the conductor is not connected or is inter- therefore be depressurized before
operator, and in observance of the local condi- rupted. starting assembly, maintenance or repair
tions for connections and local regulations work, or any system modiications or
1.4 System pressure hazard
(e.g., DIN, VDE). Significant bodily injury and system repairs.
KFG KFGS KFGL KFGC
property damage may result from improperly Depending on the model design, the product
connected products. Lubrication systems are pressurized may be able to be operated hydraulically.
during operation. Centralized lubrication
systems must therefore be depressurized
Danger! before starting assembly, maintenance
Work on products that have not been or repair work, or any system modiica-
de-energized may result in bodily injury. tions or system repairs.
Assembly, maintenance and repair work
may only be performed on products 1.5 Compressed air hazard
that have been de-energized by qualiied
technical personnel. Supply voltage The described product is pressurized
must be switched off before opening during operation. The product must
any of the product's components. therefore be depressurized before
starting assembly, maintenance or repair
The protective earth conductor (PE) work, or any system modiications or
must always be connected. Always system repairs.
ensure adequate, standard conductor Depending on the model design, the product
diameter and secure contact. may be able to be operated with compressed air.
Assembly instructions Page 11 EN
2. Lubricants
2.1 General information 2.2 Selection of lubricants
All products from SKF Lubrication in conjunction with gases, liquefied gases, Observe the instructions from the
Systems Germany GmbH may be used pressurized gases in solution, vapors, or such machine manufacturer regarding the
only for their intended purpose and in fluids whose vapor pressure exceeds normal lubricants that are to be used.
accordance with the information in the atmospheric pressure (1013 mbar) by more
product's assembly instructions. than 0.5 bar at their maximum permissible Warning!
temperature. The amount of lubricant required at
a lubrication point is speciied by the
KFG KFGS KFGL KFGC
SKF Lubrication Systems Germany Warning! Note that in rare cases, there may be lubricants
GmbH supports customers in the Only lubricants approved for the prod- whose properties are within permissible limit
selection of suitable components for uct may be used. Unsuitable lubricants values but whose other characteristics render
feeding the selected lubricant and in can lead to failure of the product and to them unsuitable for use in centralized lubrica-
the planning and design of a centralized property damage. tion systems. For example, synthetic lubricants
lubrication system. may be incompatible with elastomers.
It is important to note that lubricants are envi- maintenance, and repair of centralized
ronmentally hazardous, flammable substances lubrication systems. Leaks must be
which require special precautionary measures sealed off without delay.
during transport, storage, and processing. Lubricant leaking from centralized lubrication
Consult the safety data sheet from the lubri- systems is a serious hazard. Leaking lubricant
cant manufacturer for information regarding can create risks that may result in physical
transport, storage, processing, and environ- harm to persons or damage to other material
mental hazards of the lubricant that will be assets.
used. The safety data sheet for a lubricant can
be requested from the lubricant manufacturer. Follow the safety instructions on the
lubricant's safety data sheet.
Assembly instructions Page 15 EN
3. Overview
in
Use hard grease NLGI-2 only !
12 Shutdown OI Chapter 12
13 Maintenance OI Chapter 13
OI = Operating instructions
EN Page 16 Assembly instructions
4. Assembly
4.1 General information 4.2 Setup and attachment
Pump units of the KFG series are an integral The pump unit should be installed in a place During assembly and especially when drilling,
component of centralized lubrication systems protected from contamination, water splashes always pay attention to the following:
used in machines and systems. and vibrations. It should, however, be easily
They deliver greases up to NLGI Grade 2. The accessible so that all other installations can be Existing supply lines must not be dam-
pump units differ in terms of the size of lubricant performed without difficulty and the device can aged by assembly work.
reservoir, the lubricant filling and their control be filled easily. The fill level of the reservoir
KFG KFGS KFGL KFGC
and function monitoring. The installation of must be easily visible. The unit mounting position Other units must not be damaged by
volume-specific pump elements permits a single is vertical. Any assembly holes must be made assembly work.
unit of the KFG, KFGS or KFGL series to oper- according to the diagram on the following
ate up to three independent zones. page. Design specifications and conditions of The product must not be installed within
The KFGC series is capable of operating up to the manufacturer and the object must be ob- range of moving parts.
four independent zones, depending on the served when installing the pump unit.
task. The system can be equipped with or The product must be installed at an ade-
without functionality to monitor pressure A drilling jig can be ordered quate distance from sources of heat.
build-up and reduction. (order number 951-130-115).
Maintain safety clearances and comply
Before assembling/setting up the reservoir with local regulations for assembly and
unit, the packaging material and any shipping accident prevention.
braces (e.g., plugs) must be removed. The
packaging material must be preserved until
any discrepancies are resolved.
Assembly instructions Page 17 EN
267
225
2 kg/6 kg 10 kg/15 kg/20 kg Mounting diagram
200 13
± 0,4 Pump Dim. A Dim. B
200 size [mm] [mm]
KFG KFGS KFGL KFGC
4
116
10 kg 460
± 0,4
15 kg 342.5
216
Ø 9,0
20 kg 432.5
75
max
27
79
B
A
B
10.5
ax
175
228
in
Use hard grease NLGI-2 only ! 1
2
3
Assembly instructions Page 19 EN
max
267
225
200
13
432.5 ( 20 kg )
116
40
216
342.5 ( 15 kg )
1118 ( 20 Kg-reservoir )
(6x) 10.5
max
938 ( 15 kg-reservoir )
40
40
10 kg / 15 kg / 20 kg
116
713 ( 10 kg-reservoir )
432.5 ( 20 kg )
460 ( 10 kg-reservoir )
342.5 ( 15 kg )
267
225
11
200
Ø9
ax
(4x) 10.5
115
343 ( 6kg-reservoir)
215
229 (2 kg-reservoir)
ax
min min
in
Use hard grease NLGI-2 only !
175
175
175
Ø9
75
268
2 kg / 6 kg 10 kg 15 kg / 20 kg
EN Page 20 Assembly instructions
max
267
225
200
13
432.5 ( 20 kg )
KFG KFGS KFGL KFGC
4
max
116
40
216
342.5 ( 15 kg )
1170 ( 20 kg-reservoir)
(6x) 10.5
max
40
990 ( 15 kg-reservoir)
Flange mounting view
40
116 10 kg / 15 kg / 20 kg
432.5 ( 20 kg )
765 ( 10kg-reservoir)
460 ( 10 kg-reservoir)
342.5 ( 15 kg )
267
225
11
200
Ø9
ax
(4x) 10.5
395 ( 6 kg-reservoir)
115
215
281 (2 kg-reservoir)
ax
min min
in
Use hard grease NLGI-2 only !
228
228
75
228
1 1 1
2 2 2
2 kg / 6 kg
79
Ø9
200
268
Assembly instructions Page 21 EN
Depending on the pump unit's application (DIN 7603-A20x24-Al) can also be fitted if de-
(ProFlex/MonoFlex) and configuration (KFG/ sired. Alternatively the screw plug can be
KFGS/KFGL/KFGC), it is possible to connect ordered from SKF under order number
When ordering pump elements, the required Pump elements with spring-return pistons
delivery rate must be specified, as well as the
Delivery rate ) 1
Number of grooves Max. permiss. oper. pressure Order No.
design type (spring return pistons/ positively [cm3/min] [bar]
driven pistons).
5.0 0 200 KFG1.U0
Connection of the pump elements, Fig. 5 1) The values given here apply for a temperature of 20 °C, back pressure of 50 bar and greases of NLGI Grade 2.
M20x1,5
2 1 4 3
M14x1,5
Connection for pump elements
torque of 35 Nm.
3
3
• Switch on pump and leave running until
grease without bubbles discharges from
the pump element outlet.
• Reconnect pressure regulating valve (2) (or
lubrication line (3) to the pump element (1)
and tighten at a torque of 25 Nm.
EN Page 24 Assembly instructions
4.3.4 Pump elements with positively driven pistons 4.3.3 Assembly of a pump element with
positively driven pistons
Pump elements with positively driven pistons see Fig. 9
Delivery rate ) 1
Max. permiss. oper. pressure Labeling Order No.
[cm3/min] [bar] • Turn off pump unit.
• Unscrew and remove screw plug
5.0 250 L-0 KFG1.U0-E
(KFG1.128)
2.5 350 G-1 KFG1.U1-E Then perform the following:
KFG KFGS KFGL KFGC
the housing bore with a bar magnet (or Assembly, positively driven pump element, Fig. 9
taper-nose pliers). Section A
• Section C Carefully pull the piston (6) out of max
4.3.4 Pressure regulating valve Pressure regulating valve Pressure regulating valve, Fig. 10
3 8 300 161-210-025
1 Connections for pressure regulating valves
Pressure regulating valve with
pressure gauge A Connection for pipe Ø
P Pipe thread for pump element
6 300 161-210-046 R Grease discharge at overpressure
2 8 300 161-210-047
Cracking pressure 300 ± 20 bar
10 300 161-210-048 Cracking pressure 200 ± 20 bar
Connection for pressure regulating valve
Assembly instructions Page 27 EN
Pressure regulating valve with Only ill using clean lubricant and an
T connector output Filling, Fig. 12
appropriate illing device. Contaminated
Tube Ø Cracking pressure Order number lubricants can result in severe system
[mm] [bar]
malfunction.
6 300 161-210-038 max
P A
Nominal pipe
dimensions
Ø: 6-, 8-, 10 mm
P A
EN Page 28 Assembly instructions
As an alternative or in addition to the conical When used at very low temperatures, the
head nipple (1) the unit can also be itted with pump unit can optionally be illed via one of
a iller socket (part No. 995-000-705) (2) for the lubricant outlets using a illing cylinder (1).
illing by means of a iller pump. This is done by removing the screw plug
A corresponding coupling socket (part No. M20 x1.5 (2) from the lubricant outlet
995-001-500) (3) must be mounted on the and replacing it with a iller socket
illing pump. The cap on the iller socket must (part No. 169-000-174) (3). When illing,
be removed before illing.
KFG KFGS KFGL KFGC
995-000-705
Filling cylinder
169-000-171
Filler socket
169-000-174
Assembly instructions Page 29 EN
4.5 Electrical power supply 4.5.1 General conditions for electrical connections
Warning! KFG; KFGS; KFGL; KFGC, General conditions for electrical connections
Compare the operating voltage with the
speciications on the rating plate.
Nominal Power Power Pump Max.
Voltage consumption consumption starting current back-up fuse
(load-dependent) (max.) (ca. 20 ms)
4.6 KFG power supply and connections 4.6.1 KFG power supply 4.6.2 External control units
1
DIN EN 175301-803. to monitor the lubrication process.
There may be an additional connector for fill
2
level control on the pump housing, depending
on the pump unit model. This is to be connect-
+ KFG...DC
ed by the customer. The standard connections M
-
are presented below (variations possible in the The operating instructions/functional
X1 1 2 3
case of special designs). description of the corresponding control
unit must be observed.
KFG
31 15
PIN Description
1 (Ground) = 31
4.7 KFGS power supply and connections 4.7.1 KFGS power supply
With integrated IG502 control unit
KFGS power supply, Fig. 17 Connector pin assignment
The electrical connection is a 7-pin plug-in
connector on the base of the pump unit. PIN Color code Conductor coloring
1 BN Brown
The pump control can run in the following 2 RD-BK Red-Black
control modes: 3 BU Blue
4 PK Pink
Timer operation without system monitoring 5 BK Black
Timer operation with system monitoring 6 BK Black
Counter operation without system 7 VT-GN Violet-green
monitoring
KFGS
Counter operation with system monitoring
5 Power supplied through a Note!
4
6
1
7-pin circular connector The connector pin assignment varies
Depending on the pump unit design, an addi- depending on the operating mode.
3
7
tional plug for fill level control can be integrat- Therefore refer to the following ex-
ed into the pump housing. The standard con- amples for pin functions. Unneeded
nections are presented below. conductor ends on the cable set must
Accessories be individually insulated and secured so
that no short to ground can occur.
Description Order No.
Wiring harness, in corrugated pipe,
with socket-outlet on pump side
8 m length 997-000-760
12 m length 997-000-630
16 m length 997-000-650
EN Page 32 Assembly instructions
Programming:
- Chapter 9 of assembly instructions 4.7.2 Connectivity 4.7.3 Connectivity
Counter operation without system monitoring Counter operation with system monitoring
Control using machine pulses
(Counter mode = load-dependent lubrication) KFGS connection, Fig. 18 KFGS connection, Fig. 19
The duration of the interval time is determined
5
4
4
6
6
1
1
KFGS... KFGS...
3
7
7
by a pulse generator that sends pulses to the
2
control unit based on how long the machine X1 1 2 3 4 5 6 7 X1 1 2 3 4 5 6 7
has been running. The control unit counts the
BN
BU
PK
BN
BU
PK
BK
RD-BK
BK
RD-BK
pulses that are received and starts the pump
after the pre-set number of pulses.
The pump cycle time is defined by a time val-
KFGS
DK SL2 DK ZS
SL2
ue. Both the number of pulses that determine 2,4 W
2,4 W
the interval time and the pump cycle time can F F
31 15 31 15
be configured.
The fill level monitoring unit is internally con-
Programming: cPA, tCO, COP = OFF Programming: cPA, tCO, COP = CS
nected to the integrated pump control unit. A
fault notification can be sent to the process
control level via indicator light SL2. Connector pin assignment in counter operation
Timer mode
KFGS connection, Fig. 20 KFGS connection, Fig. 21
5
4
4
6
6
KFGS... KFGS...
1
3
3
7
7
by a time value. It is configured by entering a
2
time value in hours. X1 1 2 3 4 5 6 7 X1 1 2 3 4 5 6 7
BN
BU
PK
VT-GN
RD-BK
BN
BU
PK
BK
BK
VT-GN
RD-BK
time value in minutes.
The fill level monitoring unit (W1 control) is in-
ternally connected to the integrated pump
KFGS
DK SL2 SL1 DK SL2 PS SL1
control unit. A fault notification can be sent to 2,4 W 2,4 W
+
2,4 W 2,4 W
the vehicle control/electronics system via indi- F F
cator light SL2.
31 15 31 15
Programming: tPA, tCO, COP = OFF Programming: tPA, tCO, COP = CS
4.8 KFGL power supply and connections 4.8.1 KFGL power supply
With integrated LC502 control unit
KFGL power supply, Fig. 22 Connector pin assignment
The KFGL pump unit can be itted with a ill PIN Color code Conductor coloring
level switch of one of the following types for
indication of the “Minimum” ill level:
1 BN Brown
2 RD-BK Red-Black
Order code 1 (formerly W1 control) for
3 BU Blue
4 PK Pink
greases of NLGI≥ 2
Order code 2 (formerly W1G control) with
5 BK Black
6 BK Black
KFGL
4
6
Accessories
Power supply 5
Pin 1: OV (-)
Pin 2: 12/24 VDC (+)
Error output (Fault)
Pin 3: Fault notification (-)
Pin 4: Fault notification (+)
Input 3 (In 3)
Pin 5: External DK (-)
Pin 6: External DK (+)
Output 1 (Out 1) 1
Standard model = Disabled
KFGS
system with two main lines
Pin 3: Valve (-)
Pin 4: Valve (+)
Out 2
In 2 Output 2 (Out 1) 2
Power Standard model = Disabled
In system with two main lines
Out 1
In 1
2
7 Input 1 (In 1) 3
Pin 1: Cycle switch 1 (+)
3
1
6
4
5 Pin 4: Cycle switch 1 (-)
Input 2 (In 2) 4
Pin 1: Cycle switch 2 (+)
Pin 4: Cycle switch 2 (-)
EN Page 36 Assembly instructions
Power supply
Pin 1: OV (-)
Pin 2: 12/24 VDC (+)
Error output (Fault)
Pin 3: Fault notification (-)
Pin 4: Fault notification (+)
KFGL
Input 3 (In 3)
Pin 5: External DK (-)
Pin 6: External DK (+)
Output 2 (Out 2) 2
In 1
F ault
Pin 3: not programmed (-)
Pin 4: not programmed (+)
2
Input 1 (In 1) 3
7
3
1
4
5
KFGC
also be attached to control the reversing valves 5 BK Black VT4 +
and sensors. 6 BK Black Vt4 -
7 VT-GN Violet-green NC
Accessories
5 Power supplied through a
4
6
CAN bus connector pin assignment Reversing valve/piston detector connector pin assignment
PIN Color code Function PIN Color code Input CS2/CS3 Output VT1 to VT3
A YE Yellow CAN_H 1 BN Brown + NC
B GN Green CAN-B 2 WH White NC NC
C BK Black CAN-SHLD 3 BU Blue NC -
4 BK Black - +
Assembly instructions Page 39 EN
4.9.2 Connectivity
5
B
4
6
1 2
C
1
4 3
3
7
A
2
cation segments Assignment of the 7-pin Assignment of the Assignment of the 4-pin circular
KFGC
circular connector CAN bus connector connector M12x1
Customer-speciic variations are
possible. – + + + – + + + –+ –+ –+
CS1 CS2 CS3 V1 V2 V3
A B C
1
1
1
2
3
4
X1
2
3
4
2
3
4
2
3
4
2
3
4
2
3
4
1 2 3 4 5 6 7
M 12 x 1
M 12 x 1
M 12 x 1
M12x1
M12x1
M12x1
Legend for maximum configuration connection
CAN-BUS
BN
BU
PK
VT-GN
BK
BK
example
RD-BK
M 1 2x 1
M 1 2x 1
M 1 2x 1
M12x1
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
SL2 "Fault" indicator light F1
(can be operated as an
15 SL2
alternative in place of valve 4) CS4 (MC) V4 RD CS1 CS2 CS3 V1 V2 V3
S1
L+ + Supply voltage potential 31 30
S1 Ignition switch CS.. = piston detector V.. = reversing valves
M L+
F1 Fuse
EN Page 40 Assembly instructions
5
B
4
6
C
1
circular connector M12x1) for operation of a
3
7
A
2
progressive feeder system, no division into Assignment of the 7-pin circular connector Assignment of the CAN bus connector
lubrication segments.
KFGS...-...B...
KFGC
– + + + –
A B C
X1 1 2 3 4 5 6 7
BN
BU
PK
VT-GN
BK
BK
RD-BK
connection example
M12x1
1
2
3
4
2
SL2 "Fault" indicator light F1
200 bar
max
4
6
2
Assembly instructions Page 45 EN
4.11.4 Pump unit ill level control 4.12 Lubrication line connection 4.13 Lubrication line arrangement
Visual The lubrication line must be connected to the The pipes, tubes, shutoff valves and directional
lubrication unit in such a way that no forces control valves, fittings, etc. that will be used
The transparent lubricant reservoir allows for can be transferred to the assembled lubrica- must be designed for the maximum operating
visual ill level control. This must be performed tion unit (stress-free connection). pressure of the lubrication unit, the permissi-
on a regular basis for safety reasons. ble temperatures and the lubricants that will
Warning! be delivered. Furthermore, the lubrication line
The ittings used to connect the
4.14 Progressive system ventilation 4.15 Single-line system ventilation 4.16 Note on the rating plate
Fill pump with lubricant. Fill pump with lubricant. The rating plate of pump units KFG and KFGS
Remove main lines on unit. Remove main lines (pressure relief valve as displays important speciications such as type
Allow pump to run until lubricant without
designation and short material description (or
necessary) on unit.
Allow pump to run until lubricant without
customer number).
bubbles is discharged at the straight con-
To avoid loss of this data in case the rating
nector of the pump element. bubbles is discharged at the straight con-
Mount main lines.
plate becomes illegible, these characteristics
nector.
Allow pump to run until grease can be seen Mount main lines.
should be entered in the following table.
KFG KFGS KFGL KFGC
Serial number
4.17 Notes on the CE marking
The CE marking is performed following the require-
ments stated in the applied standards:
The safety instructions listed in Chapter 1, SKF components or SKF spare parts
"Safety instructions," of the assembly instruc- Caused by inappropriate usage
tions also apply without restrictions to these Resulting from improper assembly,
operating instructions. coniguration or illing
Resulting from improper response to
malfunctions
Caused by independent modiication of
system components
In addition to the operating instructions, Only media approved for these types of
general statutory regulations and other pump units may be used. Unsuitable
binding regulations for accident preven- media may result in pump unit failure and
tion and for environmental protection potentially severe bodily injury and property
(recycling/disposal) must be observed damage.
and applied.
3. Transport, delivery, and storage Page 51 EN
The assembly procedure for KFG pump units is Pump units of the KFG, KFGS, KFGL and KFGC Pump units of the KFG, KFGS, KFGL and KFGC
described in detail in the assembly instructions series are electrically driven reservoir pump series are characterized by their compact con-
associated with these operating instructions. units (piston pumps) available with and without struction and are divided into the assemblies
Information/instructions about assembling the an integrated control unit. The pump ensures for pump housing, lubricant reservoir, control
KFG (S) (L) (C) pump units beyond the scope of demand-based supply of lubricant to central- unit, and ill level monitoring.
the assembly instructions are contained later ized lubrication systems with progressive feed- A short description of the individual assem-
blies follows below.
KFG KFGS KFGL KFGC
A grease return can also be attached. A display There is a choice of two fill level switches for for differing lubricant requirements; the lubri-
and control screen is mounted on the front monitoring of the minimum pump fill level. Fill cation lines can be controlled and monitored
side of the KFGS or KFGL design, while the level control W1 (order code 1) and fill level individually.
KFGC design has a display attached. An IrDA control W1G (order code 2) are used with lu-
interface is integrated into this, which can op- bricants up to NLGI Grade 2≥ The difference
5.3 KFG pump units
tionally be used to program the pump. between the two fill level controls is that fill
Pump units of the KFGS series are reservoir Pump units of the KFGL series are reservoir A piston detector is used to monitor the feed-
pump units with an IG502-2-I integrated con- pump units with an LC502 integrated control ing operation on progressive systems; a pres-
trol unit with a control display. Parameters for unit with a control display. The control unit is sure switch is used for single-line systems.
interval times (timer), interval pulses (counter) pre-programmed with standard settings and
and pump cycle times (contact) can be entered easy to operate The KFGL pump is available in the same reser-
through the control unit. The control unit can be used to set the pump voir capacities and voltage designs and with
A piston detector is used to monitor the feed- run time either: the same grease follower plates as the KFG/
ing operation on progressive systems. based on pump speed KFGS series.
based on time (hours and minutes) or
KFGS KFGL
The KFGS pump is available in the same reser- machine cycles (load-dependent) The fill level of the pump units is monitored
voir capacities and voltage designs as the KFG using the fill level switches mentioned in
series. Sectional lubrication is available for differing Chapter 5.2.3 (operating instructions) and
The fill level of the pump units is monitored lubricant requirements; the lubrication lines Chapter 4 (in the assembly instructions.
using the fill level switches mentioned in can be controlled and monitored individually
Chapter 5.2.3 (operating instructions) and The LC502 also offers a wide range of options The signals from minimum fill level monitoring
Chapter 4 (in the assembly instructions). for monitoring functions and processes, with are processed by the integrated KFGL control
The signals from minimum fill level monitoring up to three lubrication zones able to be moni- unit.
are processed by the integrated KFGS control tored independently.
unit.
The LC502 is fitted with integrated tempera-
ture overload protection and continuous sys-
tem monitoring with fault detection and fault
analysis.
5. Design and function Page 55 EN
Pump units of the KFGC series are pump units In addition to valve control, the outputs can This allows the causes of operational faults to
from the KFG series with an integrated CAN also be configured as digital outputs for other be determined more easily.
bus control unit. purposes. The flexible parameters and configuration op-
The integrated LC-CAN 5000 control unit of- In addition to the above-mentioned outputs, tions allow custom lubrication concepts to be
fers the following special features: up to four digital inputs are available, e.g., for implemented for each individual lubrication
connecting piston detectors, pressure switches zone in the system. The control unit can store
KFGC
or other switching contacts. A detailed de- up to 16 sets of parameters. Each set of pa-
CAN bus interface (SAE J1939), which scription of the electrical connections can be rameters contains all the information required
allows units to be seamlessly integrated found in Chapter 4 in the assembly to control and monitor the lubrication process.
into the CAN bus networks. instructions. This means that different lubrication scenarios
The lubrication system can be monitored,
operated and conigured through the CAN
can be prepared and saved then called on
The control unit's comprehensive monitoring when needed.
bus.
The pump can optionally be conigured
functions allow potential faults to be detected Chapt er 4 in the assembly instructions con-
early. This includes, among other things, moni- tains instructions on configuring the system.
and operated via the IrDA interface.
toring the fill level in the lubricant reservoir You can find further descriptions of the SKF-
Moreover, the control unit is able to control (minimum), monitoring the signal lines on at- KFGC-CAN bus system under the document
and monitor up to four independent zones and tached components for line breakage, and numbers 951-170-205 or in the CAN bus
to supply them from a single pump unit. monitoring the switching outputs for short control system description 951-130-502-EN.
To achieve this capability, electric switch valves circuits.
which are controlled based on the parameters
set for each individual lubrication zone are Important system events such as a low fill level
placed in the main line. The control unit has in the lubricant reservoir (minimum) are saved
up to four solid-state switching outputs for this by the control unit and given a time stamp.
purpose.
EN Page 56 6. Functional description in progressive systems
KFG
6
R
R
4 5
P
2 Fill level switch 6 Master feeder
3 Pump element with pressure regulating valve 7 Secondary feeder
4 Electrical pump connection 8 Lubrication points
A
EN Page 58 6. Functional description in progressive systems
6.2 Progressive system with a Example of progressive system with KFS/KFGL pump unit, Fig. 4
KFGS or KFGL pump unit
9 9
The general functional description for progres-
sive systems with a KFG pump unit also applies max
10
for the design with KFGS and KFGL pump 3
control.
4 6
be adjusted independently, including on
5
monitored systems 7
Recording of remaining intervals and
remaining lubrication times 1
2 6
Non-volatile memory with PIN code
protection
Connectivity for inductive piston detector
to monitor the feeder function
Connectivity for external pushbutton Progressive system with piston detector
Internal ill level monitoring, lubrication
cycle stop and fault notiication remain 1 KFGS unit 6 Lubrication lines
on display in case the level falls below 2 Power supply 7 Piston detector
minimum 3 Fault indicator light 8 Master feeder
Fault memory 4 Fill level switch 9 Secondary feeder
5 Pump element with pressure regulating valve 10 Lubrication points
6. Functional description in progressive systems Page 59 EN
6.3 Progressive systems with When CAN commands are used for control, the valves in a carefully coordinated sequence
KFGC (CAN bus) pump unit valve opening must be ensured by selecting so that only one valve is opened at a time.
The general functional description for progres- the appropriate contact and interval times or
sive systems with a KFGS pump unit also by using appropriately programmed processes
applies for the design with CAN bus pump in the external lubrication program to switch
control.
The integrated LC-CAN 5000 control unit per-
mits the lubrication zone of a progressive feeder Example of progressive system with KFGC pump unit (CAN bus), Fig. 5
KFGC
system to be distributed into individual lubrica-
tion segments which can be configured with max
A general single-line system consists of a The pump element delivers the lubricant ac- A pressure regulating valve can be installed
pump unit with pump element and pressure cording to the capacity of the connected sin- single-line systems to prevent excessive oper-
regulating valve, pressure relief valve and fill gle-line distributors. There are both prelubri- ating pressure in the lubrication system. The
level monitoring, main line and single-line cation distributors and relubrication pressure regulating valve (see Technical Data,
distributors. distributors. Chapter 4.3.5 in the assembly instructions)
When the pump motor is turned on, the piston opens when operating pressure exceeds its
7.1.2 Pressure relief valve
pump delivers lubricant from the reservoir to cracking pressure. The lubricant escapes
the lubricant outlet. The pump element at- through the valve or flows back into the reser-
tached to the outlet meters the lubricant and In order to allow another lubrication cycle after voir. This protects the pump unit against
delivers it further through the pressure relief metering is complete, the main line must first overload.
valve attached to the pump element on to the be relieved of pressure, which also relieves the
main line. The lubricant flows through the downstream single-line distributors. The main
KFG
main line to the single-line distributors, where line and single-line distributors relieve into the Pressure relief valve/pressure regulating
it is metered and passed to the lubrication lubricant reservoir. valve, Fig. 6
points. This is performed during or after the
pump cycle time, depending on the type of dis-
tributors used (prelubrication or relubrication
distributors). The pressure relief valve switches
after pressure build-up is complete. After the
main line has been relieved, the pump unit is
now prepared for another lubrication cycle.
7. Functional description in single-line systems Page 61 EN
Example of single-line system with KFG pump unit, Fig. 7 Single-line system with KFG pump unit
1 KFG unit
6
7 2 Pump element with pressure relief valve
with integrated pressure regulating valve
3 Fill level switch
5 4 Main line
5 Single-line distributor
6 Pressure gauge for pressure build-up mon-
itoring
7 Pressure switch for pressure build-up
monitoring
KFG
5
max
5 1
2 3
4
EN Page 62 7. Functional description in single-line systems
Interval time and contact time can be ad-
justed independently for pressure-moni-
tored and pressure-controlled systems
KFGL
Example of single-line system with KFGL pump unit, Fig. 8 Legend to figure of KFGL single-line system
KFGL
6 Pressure gauge for pressure build-up moni-
toring
7 Pressure switch for pressure build-up
monitoring
5
max
1
5
4 2 3
1
2
3
EN Page 64 7. Functional description in single-line systems
7.3 Functional description in single-line 7.3.1 Systems with 3/2 directional 7.3.2 Multiple lubrication zones
systems with a KFGC (CAN-Bus) solenoid valves
pump unit
Directional solenoid valves can be used to cre- Using the integrated LC-CAN 5000 control
The general functional description for sin- ate a single-line system with up to four lubri- unit, a single-line system can be divided into
gle-line systems with a KFG pump unit also cation zones. The system can be equipped with up to four individually controllable lubrication
applies for the design with CAN bus pump or without functionality to monitor pressure zones. This is performed using electric switch
control. build-up and reduction. valves which separate the individual lubrication
zones from each other.
KFGC
max
Legend
8. Commissioning
8.1 General commissioning
The reservoir unit described here functions Warning!
automatically. The lubricant transport in the Different lubricants cannot be mixed, Before the product is commissioned, all elec-
lubrication lines should, however, be subjected as mixing may result in damage and trical connections must be inspected.
to regular visual inspection. necessitate costly and complicated
cleaning of the product/centralized The lubricant may only be fed without bubbles.
The lubricant fill level in the lubricant reservoir, lubrication system. The lubricant reservoir, if present, must be
if present, should likewise be subjected to reg- It is recommended that an indication of filled with clean lubricant without introducing
The display and control unit is protected from Three-digit LED display Values and operating status
water splashes and mechanical damage by a
transparent plastic cover. The cover must be PAUSE LED Interval time
removed to program the unit and then re-
mounted afterwards. CONTACT LED Display contact time (pump operation)
progressive systems
2
FAULT LED Fault notification
Three-digit LED display, Fig. 11 t = TIMER The control unit is functioning as CONTACT = time during
CO = CONTACT a timer and is currently in a pump which the pump delivers
cycle (CONTACT). lubricant; entry and display
KFGS
value in minutes.
Fault Cycle Switch No signal from piston detector The control unit is currently
Fault: during pump cycle. in FAULT mode.
Piston detector The operational sequence has
been stopped.
KFGS
Fault Pressure Switch No signal from the pressure The control unit is currently
Fault: switch during pump cycle. in FAULT mode.
Pressure switch The operational sequence has
been stopped.
Operation Hour Meter The values shown after this The control unit is currently
Operational hours are the number of hours the in FAULT mode.
counter control unit has operated. The operational sequence has
been stopped.
Fault Hour Meter The values shown after this are the number of fault hours, i.e.,
Fault-hours counter the amount of time the vehicle or machine was operated in
FAULT mode.
Block mode No signal from the piston detector. Unlike in normal mode, the
control unit is still the monitoring sequence. A fault notification is
issued if the fault remains for three pump cycles times.
9. KFGS control unit Page 69 EN
Operating voltage is present on pump unit Value for CONTACT can be changed.
and control unit, system is currently in oper-
ating status CONTACT (pump motor ON)
A cycle switch (CS) is used for system Monitoring type can be switched off in pro-
monitoring. On progressive feeders, gramming mode.
CS monitoring is performed during the pump COP = CS monitoring is active
cycle (CONTACT). COP = OFF monitoring is switched off
1 The LED lights up when a signal is received.
KFGS
PS System monitoring using pressure switch
2 (PS)
The operating voltage is present on the pump unit and control unit. The control unit is in
operating status FAULT. The cause can be accessed via the LED display and shown as a fault
code by pressing the pushbutton. The operational sequence has been stopped.
EN Page 70 9. KFGS control unit
Key Function
Switch on the display in display mode, call up last parameter in programming mode,
reduce displayed value by 1.
KFGS
KFGS
Display is in hours
8
or or
10/11
KFGS
+
Example: 1st part 2nd part of total value
of total value Total value: 00533.8 h
Write down. Maximum value: 99999.9 h
13/14
+
Example: 1st part 2nd part of total value
of total value Total value: 00033.8 h
Write down. Maximum value: 99999.9 h
Display clears
Oh and Fh values are stored in EEPROM and cannot be deleted.
9. KFGS control unit Page 73 EN
KFGS
3 Interval time 1 h (factory setting)
(display in hours)
Press briefly
9.3.2 Change lubrication interval times
4 Set new value
Example: 6.8 h = 6 h 48 min
Note on step 2
If the 000 factory setting has been
changed, the changed code must be 5 Display parameter:
selected using the keys and "Pump cycle time Timer operation"
conirmed using the
Press briefly "CONTACT" LED flashes
key. (confirm new value)
8
Press briefly
(confirm new value)
KFGS
When system monitoring is active, you can se- 2 Automatic display of first parameter:
"pause in timer operation"
lect monitoring via piston detector or monitor- Press briefly "PAUSE" LED flashes
ing via pressure switch. (confirm code)
KFGS
4 System monitoring switched off
(factory setting)
Press briefly
5
Press either until or
6
Press briefly Confirm new setting
Press briefly to
confirm counter operation
KFGS
(confirm key)
4
Press briefly Display flashes
Warning! (confirm code)
Do not enter the digits 321 as the new 5 new code is set
code. Example: 666
Press either until Warning! Do not enter 321.
Press briefly
9.3.6 Programming ranges 9.4 KFGS operating modes 9.4.2 Counter operation
The interval depends on the number of pulses;
9.4.1 Timer operation
Programming ranges the pump cycle time is time-dependent.
The interval and pump cycle are An external pulse generator must be attached
Function Programming range 1)
time-dependent. as described in Chapter 4 in the assembly
Interval time 0.1 h to 99.9 h instructions.
Pump cycle time 0.1 min to 99.9 min
Pulses 1 to 999 The lubrication cycle is controlled by the pre-
set, time-dependent values for PAUSE and PAUSE: Values in pulses
1) For the permissible setting range for KFG(S) 90-264 VAC, CONTACT. CONTACT: Values in minutes
see Technical Data, Chapter 13.
PAUSE: Values in hours A switch opens and closes based on machine
CONTACT: Values in minutes movements, revolutions, etc.
KFGS
9.4.3 No system monitoring 9.5 Fill level monitoring 9.5.1 Monitoring via piston detector
In this operating mode, the lubrication cycle If ill level monitoring is installed, it is Only possible for centralized lubrication
is controlled solely by the pre-set values for always active. systems with progressive feeders.
PAUSE and CONTACT. If the level in the lubricant reservoir falls below For greases up to NLGI Grade 2.
the minimum fill level, the lubricant cycle is
Monitoring must be switched off. stopped and a fault notification is issued on the
COP = OFF System malfunctions are display. The piston detector monitors the movement of
not automatically detected or displayed. pistons in the progressive feeder during
Display mode, Fig. 16 CONTACT time (pump cycle time). The follow-
ing monitoring setting must be activated in
9.4.4 With system monitoring
programming mode:
KFGS
In this operating mode, system functions are COP = CS (see Chapter 9.3.3).
additionally monitored using external switches.
The following can be monitored:
max
10
1
6
5
6
KFGS
2
7 8
1
2
3
6
3
KFGL
Control screen KGFL, Fig. 18 no error detected on pump control unit (error is
outside pump)
PAUSE LED Display pause time
Yellow LED lights up = active pump pause time on
1 at least one main line
2 CONTACT LED Display contact time (pump operation)
3 Green LED lights up = active pump run time
1 = Output 1 Display pump output 1 to 2
2 = Output 2 LED on output 1 or 2 lights up = pump output
1 1 or 2 is switched on. Lubricant is delivered via the
2 indicated line (1 or 2)
3
3 = Inputs Display all signal inputs
LED lights up = signal change on input port
The LED lights up for approx. 1 second each time
the signal on the input port changes.
ENTER key Confirm value
Confirm input and values
EN Page 82 10. KFGL control unit
Control screen KGFL, Fig. 19 The control unit's display has three rows of eight Main menu KGFL, Fig. 20
characters each. Only three options are shown
in menu windows containing more than three
1 1
available choices. Press the <up/down> arrow Info
2 keys to access further options. Conig
2
3 3
Status
Configuring a setting on the device involves
consecutively opening multiple menu windows.
KFGL
The current device setting is then shown on a
black background.
Not all possible options are displayed in the The main menu shows the following options:
settings. Only settings that are available and Device-specific information
permitted for the selected device type (ProFlex Device configuration
or MonoFlex) and the current device settings Status information
are shown.
Note!
The first menu level shows language selection. The Service menu selection is pass-
The language that is currently selected flashes. word-protected and can only be
Upon confirmation, the main menu will be dis- accessed by SKF employees.
played in the selected language.
EN Page 84 10. KFGL control unit
Base and main menu Information mode is used to query the hard-
ware identification code and the runtimes
Step Key Display Description stored thus far for the system, motor, and err
1 Entry mask/language selection time (system runtime, motor runtime, error
The German version is active by default
English (flashing) time).
German Press the “up” arrow key to change to the
English version
Press the Enter key to confirm. Note!
2 Main menu No values can be entered or modiied
KFGL
Information mode
2 Main menu
Info
Press the ENTER key to go to the Info menu.
Conig
Status
3
KFGL
Info menu
Serial number
Firmware You can switch between menu items using <arrow key up> and <arrow key down>.
Sys time
Press the ENTER key to go to the selected menu.
Mot time
Press the ENTER key
Err time
4 Serial number
Sys time Each control unit has an assigned serial number that can be viewed by pressing the ENTER key.
ØØØØØh Firmware
This is the current version number of the software and can be viewed by pressing the ENTER key.
ØØm ØØs Sys time
This displays the total running time (on-time) of the control unit in hours, minutes, and seconds.
Mot time Mot time
ØØØØØh This displays the total runtime of the pump motor in hours, minutes, and seconds.
Err time
ØØm ØØs This displays the total time of the current error (if present). If there is currently no error state, the display
shows the sum time of all errors detected thus far.
Err time Press the <<arrow key left> to return to the main menu.
ØØØØØh <Press <arrow key left>
ØØm ØØs
EN Page 86 10. KFGL control unit
When the correct password is entered, Conig Press the ENTER key to go to the
all currently running lubrication proce- Config. menu.
dures are stopped and the coniguration
Status
3 Config. menu
mode starts.
Display Display
Edit Press the ENTER key to go to the Configuration
If the configuration data will be viewed and not menus. Here you can view the configurations for:
modified, the <Config. menu> will appear upon System
confirmation by pressing the ENTER key. Settings
Inputs
No changes can be made in this mode. Outputs
The active configuration or selection will flash.
Data cannot be entered or changed in display
Selection in coniguration mode is mode.
performed by briely pressing one of the
keys.
10. KFGL control unit Page 87 EN
5 Password menu
KFGL
Password The following request for a password prevents changes being made by unauthorized persons.
00000000 Press < <arrow key up> to increment the number by 1, up to 9.
Press < <arrow key down> to decrement the number by 1, up to 0.
Press < <arrow key right> to move to the next password number (max. 7)
Press the ENTER key
Pressing the ENTER key gives access to the following configuration menus
or:
Press „ <<arrow key left> to return to the main menu.
6 Configuration sub-menu selection
System
Press the ENTER key to go to the Config. menu.
Settings
Inputs
Outputs
Default
Reset
New Pwd
EN Page 88 10. KFGL control unit
KFGC
White BUS LED Lights up when communication with
Display KFGL, Fig. 22 the CAN network has been successfully established.
Yellow CS/MC LED Lights up briefly when the control unit detects a signal
edge at an input from a piston detector (CS), pressure
switch (PS) or from the machine contact (MC).
Red FAULT LED LED lights up: Indicates a fault that does not
immediately influence the lubrication
program (e.g., break in valve cable).
The lubrication program continues
despite the fault notification.
Display KFGL, Fig. 23 Continuation of "Display and control elements of the KFGC control screen" table
12. Shutdown/disposing
12.1 Temporary shutdown 12.2 Permanent shutdown
The described product can be temporarily shut If the product will be permanently shut down,
down by disconnecting the electrical supply the local regulations and laws regarding the
connections. The instructions in the Chapter disposal of contaminated equipment must be
"General information" in these assembly in- observed.
structions must be observed when doing so.
Warning!
Danger! SKF Lubrication Systems Germany GmbH Dismantling of the product or individ-
Work on products that have not been products are low-maintenance. However, all ual parts thereof within the statutory
de-energized may result in bodily injury. connections and fittings must be regularly in- warranty period is not permitted and
Assembly, maintenance and repair work spected for proper seating to ensure proper voids any claims.
may only be performed on products function and to prevent hazards from arising.
that have been de-energized by quali- Only original spare parts from SKF
ied technical personnel. Supply voltage If necessary, the product can be cleaned using Lubrication Systems Germany GmbH
must be switched off before opening mild cleaning agents that are compatible with may be used. Unauthorized alterations
KFG KFGS KFGL KFGC
any of the product's components. the product's materials (non-alkaline, non- to products and the use of non-original
soap). For safety reasons, the product should spare parts and accessories are prohib-
Danger! be disconnected from the power supply and ited and nullify the statutory warranty.
Centralized lubrication systems are the hydraulic and/or compressed air supply.
pressurized during operation. Central- SKF Lubrication Systems Germany GmbH shall
ized lubrication systems must there- Do not allow any cleaning agent to enter the not be held liable for damages resulting from
fore be depressurized before starting interior of the product during cleaning. improperly performed assembly, maintenance
assembly, maintenance or repair work, or repair work on the products.
or any system modiications or system It is not necessary to clean the interior of the
repairs. product if the product is operated normally and
intercompatible lubricants are used.
Danger!
The described product is pressurized The interior of the product must be cleaned if
during operation. The product must incorrect or contaminated lubricant is acciden-
therefore be depressurized before tally filled into the product. If this occurs,
starting assembly, maintenance or re- please contact the Service department of SKF
pair work, or any system modiications Lubrication Systems for assistance.
or system repairs.
13. Maintenance and service Page 93 EN
The following maintenance table contains an The following maintenance and repair work If you encounter problems or have any ques-
overview of the inspections and maintenance must be performed on a regular basis: tions, please contact our sales and service
work that must be performed on a regular centers or our representatives abroad.
basis. Check of ill level in lubricant reservoir A list with current addresses is available on the
Regularly inspect system components Internet at:
The maintenance intervals depend on custom- for leaks www.skf.com/lubrication
Visually inspect lubrication of bearings
Maintenance work
Check of fill level in lubricant Refill if necessary. Depends on planned lubricant consumption
reservoir
Inspection of system com- Parts that exhibit leaks must be replaced. Please contact After each refill of the lubricant reservoir or after
KFG KFGS KFGL KFGC
ponents (lubricant lines, an SKF service office long operational pauses before commissioning the
connection points, seals, etc.) system
for leaks.
Visual inspection of bearings' In case of insufficient bearing lubrication, a fault in the In conjunction with lubrication reservoir filling.
lubrication lubrication system or incorrect system configuration is
the probable cause.
Observe the instructions contained in these operating
instructions. If necessary, please contact an SKF service
office.
KFGS; KFGL; KFGC
Check of basic function of To inspect the basic functions, trigger an interim lubrica- After each lubrication reservoir filling
control unit and system tion by pressing the key or send the corresponding
components CAN command.
Inspection of electrical cables Damaged cables must be replaced. Please contact an After long operational pauses before commission-
for damage SKF service office ing the machine/vehicle
Inspection of electrical con- Tighten loose contacts. Clean any corroded electrical Whenever maintenance is performed, and at least
nections and contacts for firm contacts with a wire brush, then apply a small amount of once every six months
attachment and corrosion contact grease after installation
14. Operational and pump faults Page 95 EN
Pump malfunctions
Pump does not deliver Suction problems due to air pockets in grease • Dismantle pump element and operate pump using key until
any lubricant, although grease discharges from outlet on housing.
agitator is rotating.
Pump element does not build up pressure, pump • Replace pump element
element is worn out. (This is indicated when the Note: metering is indicated by grooves.
outlet can be closed with a finger once the main
line is removed.)
Lubricant too stiff • If necessary, adjust lubricant to work properly at lowest working
temperature.
Pressure regulating System pressure is over 200/300 bar, e.g., due to • Check system and repair/rework the system so the maximum
valve on pump opens feeder blockage or blocked lubrication point. system pressure at 20 °C is 200 bar.
and lubricant leaks out
Valve is damaged or contaminated, so it does not • Replace pressure regulating valve.
close properly.
14. Operational and pump faults Page 97 EN
14.2 Malfunctions on KFGS pump unit 14.2.1 Display faults 14.2.2 Delete fault notiication
KFGS
No signal from piston detector
LED display, Fig. 24 during pump cycle. from operating the machine without
(see Chapter 9, Block Operation) lubrication.
Fault Pressure Switch:
No signal from the pressure The time during which the control unit
switch during pump cycle. and pump unit have been operated
Fault Low Level: without lubrication is stored as fault
The level in the reservoir has hours Fh in the EEPROM and cannot be
fallen below the minimum fill
level. The further operational deleted.
sequence has been stopped.
EN Page 98 14. Operational and pump faults
Fault types
Malfunction A fault has occurred that affects -LED lights up Insufficient number of piston Block operation up to con-
the proper functioning of the detector signals from a figured number of repetitions
lubrication system. lubrication segment during
the pump cycle time - If the piston detector signal has
KFGS
The lubrication points may still not been received, the valve
not be supplied with adequate is closed and a fault notification is
lubrication because a malfunc- generated.
tion has affected the proper
functioning of the lubrication
system.
KFGS
of the unit. The current counter reading can No signal from piston detector during
be read in display mode in two blocks of three pump cycle:
digits each by calling up the parameter Fh Normal operation is interrupted. Three pump cycles and two block pauses with-
(see Chapter 8). Block pause begins with query to piston out signal from the piston detector:
The maximum reading that can be displayed is detector Block operation is aborted
99 999.9 hours. No signal from piston detector during block Malfunction notiication is issued.
The smallest recordable interval is pause:
0.1 hours = 6 minutes. The memory cannot Second lubricating cycle begins in block Duration of block pause
be deleted. operation
Pause Normal operation blo
tPA block pause
As soon as a signal is received from the piston
detector, block operation is aborted and the 0.1 h = 6 min 6 min
0.2 h = 12 min 12 min
normal lubricating cycle starts with a pause.
0.3 h and longer 15 min
14.3 Malfunctions on KFGL pump unit 14.3.1 Display faults 14.3.3 Fault types
All fault notifications are displayed by the Warning! 14.3.4 Fault notiications
LED . Determine and remedy the cause of
faults before deleting fault notiications. Detailed, separate operating instructions for
Key to LED display: The user is liable for damages resulting the IC502 control unit are supplied together
Red LED flashes = error detected from operating the machine without with these assembly instructions.
lubrication. Chapter 10 of these operating instructions con-
Red LED lights up = fault on a signal input, tains the operational and pump faults for the
no error detected on pump control unit LED display, Fig. 26 KFGL unit.
KFGL
14.3 Malfunctions on KFGC pump unit 14.3.1 Faults detected by control unit
Protective measures that must be taken for Continuation of "Technical Data" table
operation according to the intended use in
machinery: Data universally applicable to KFG, KFGS; KFGL; KFGC
KFG; KFGS; KFGL, KFGC... 24 VDC: Description Key data/Display
(PELV)
Disconnect the unit for insulation and
Pump starting current (approx. 20 ms) 9A 4.5 A
Max. back-up fuse 5 AT 2) 3) 3 AT 2) 3)
voltage inspection according to Fill level switch W1 NLGI 2
EN 60204-1 1992 Fault notified by pulse
Fill level switch W1G NLGI 2
Fault notified by non-dry contact
Fill level switch W2 NLGI ≤ 1
Fault notified by capacitive proximity
switch
Electrically controlled pressure relief valve 12/24 VDC or 230 VAC
see Chapter 4.10, Page 41
Weight with full lubricant reservoir kg
2 kg version 7.5
6 kg version 13.5
10 kg version 27.0
15 kg version 34.5
20 kg version 41.5
Description Value
12/24 VDC 90...264 VAC
Perm. operating temperature with spring return pump elements -25 °C to +70 -25 °C to +60 °C
°C
Perm. operating temperature with spring return pump elements -30 °C to +70 -30 °C to +60 °C
KFGC data
Description Key data
Switching outputs All types
Type Solid-state output, short-circuit-proof and overload-proof
16. Accessories
Accessories
Double-pin plug (T-connector) Double-pin plug (two-way distributor) (for connecting to the M12x1 plug on the pump 179-990-700
with 2x M12x1 outputs for piston detector and separate indicator lamp)
M12x1 angle plug without cable, with 4 pins, protection class IP 67 (mounted) 179-990-372
M12x1 plug, straight with 5 m cable, 4x 0.25 mm , , protection class IP 68 (mounted)
2
179-990-600
M12x1 angle plug with 5 m cable, 4x 0.25 mm , protection class IP 68 (mounted)
2
179-990-601
Cable socket according to Type A (ISO 4400), pivoted, without LED, 1.5 mm , line diameter 6 mm to 9 mm
2
179-990-034
DIN 43 650
Cable socket according to Type A (ISO 4400), pivoted, without LED, 1.5 mm2, , line diameter 4.5 mm to 7 mm 179-990-147
DIN 43 650
Cable socket according to Type A (ISO 4400), pivoted, with rectifier and yellow LED, for connected on MonoFlex 24-1882-2167
DIN 43 650 Pressure relief valve, version 230 VAC.
Piston distributor for IGZ51-20-S3-E Pulse generator/counter with adjustable interval time, interval time extension, monitor-
single-line systems ing of pressure build-up and reduction, adjustable delay time and connectable non-vola-
tile memory in case of power failure
Progressive systems IGZ51-20-S7-E Same as IGZ51-20-S2, but with fill level switch as NC contact,
pump cycle time = set monitoring time
Progressive systems IGZ51-20-S8-E Pulse generator/counter with selectable intermittent or continuous pump operation,
prelubrication, selectable interval time and monitoring time, monitoring of fill level,
pump cycle time and pulses, and non-volatile memory in case of power failure
951-170-213-EN
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without permission of SKF Lubrication Systems Germany GmbH. Every care has been taken to ensure the accuracy
of the information contained in this publication. However, no liability can be accepted for any loss or damage,
whether direct, indirect or consequential arising out of use of the information contained herein.
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. Not all lubricants can be fed using centralized lubrication systems. SKF can, on request,
inspect the feedability of the lubricant selected by the user in centralized lubrication systems. Lubrication systems
and their components manufactured by SKF are not approved for use in conjunction with gases, liquefied gases,
pressurized gases in solution, vapors or such fluids whose vapor pressure exceeds normal atmospheric pressure
(1013 mbar) by more than 0.5 bar at their maximum permissible temperature.
Hazardous materials of any kind, especially the materials classified as hazardous by CLP Regulation EC
1272/2008 may only be used to fill SKF centralized lubrication systems and components and deliv-ered and/or
distributed with the same after consulting with and receiving written approval from SKF.
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PF 970444 · 12704 Berlin · Germany
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