Reservoir pump units of the KGF series (S) (C) for use in vehicles in automatic oil or grease lubrication systems

Transcription

1 -05-EN -058-US Reservoir pump units of the KGF series (S) (C) for use in vehicles in automatic oil or grease lubrication systems General Information Pump units of the KFG, KFGS and KFGC (CAN bus) series are electrically driven reservoir pump units available with and without an integrated control unit. The pump provides ondemand lubricant supply to centralized lubrication systems with progressive feeders or single-line distributors on machines, systems and vehicles.the pump units differ in terms of the size and type of lubricant reservoir, the lubricant filling and their control and function monitoring.powerful CAN bus versions allow one unit and a special valve to supply up to four independent zones according to demand. Application Pump units of the KFG, KFGS and KFGC (CAN bus) series are utilized in oil and grease lubrication systems for on-road and off-road vehicles.examples include commercial vehicles (on-road), construction and farm machinery and forklift applications, as well as special-purpose vehicles such as container loading devices and deep mining vehicles. Advantages Sturdy design with to pump elements Compact and reliable High-pressure technology with agitator is suitable for low working temperatures and and standard greases up to NLGI Grade and low working temperatures Control unit with memory and system monitoring function Optional CAN bus control for integration in application-specific control systems Extensive accessories program with regard to system control options and applicationspecific requirements

2 Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication Table of Contents Distinguishing features of the pump units KFG pump unit KFGS pump unit KFGC (CAN bus) pump unit Design Pump housing Assembly holes Lubricant reservoir Pump element Pressure regulating valve KFGS control unit KFGC (CAN bus) Functional description of progressive system with KFG pump unit 5 Functional description of progressive system with KFGS pump unit 5 Functional description of progressive system with KFGC (CAN bus) pump unit 5 KFG pump unit 6 Dimensions 6 Fill level monitoring 7 Fill level switch type: W 7 Fill level switch type: WG 7 Function 7 Pressure regulating valves 8 Pump elements 8 General conditions for electrical connections 9 Power supply / VDC 9 Distinguishing features of the pump units In contrast with the KFG pump unit, which can only be equipped with external pump control, the KFGS pump unit contains an internal control unit. This control unit can configure basic settings such as timer operation (pause + run time = time-dependent) or counter operation (pause = pulse-dependent, run time = time-dependent). Fill level control is also monitored by the pump control unit. The KFGC (CAN bus) version is based on the KFGS series. Furthermore, it is capable of controlling up to four independent zones via the CAN bus. The pump can optionally be programmed, operated and its data read via an IRDA interface KFGS pump unit 0 Dimensions 0 IG50--I integrated control and monitoring unit Fill level monitoring Pressure regulating valves Pump elements General conditions for electrical connections Settings for progressive lubrication Connectivity for counter operation without system monitoring Connectivity for counter operation without system monitoring Connectivity for counter operation with system monitoring Connectivity for timer operation without system monitoring 5 Connectivity for timer operation with system monitoring 5 KFGC (CAN bus) pump unit 6 Dimensions 6 LC-CAN5000 integrated CAN bus control unit with display 7 Connections 8 Connectivity 8 General conditions for electrical connections 8 Accessories 9 KFG - IG50--E electronic control unit 9 Pressure regulating valves with T connector output for progressive systems Pressure gauge Connecting piece for pressure gauge Pressure gauge screw connection with gasket Filling cylinder with connecting piece Filling device with quick-action coupling Topping-up pumps Explanation of order codes Item Description Unit components Assembly holes Lubricant reservoir Pump element Pressure regulating valve 5 Conical head nipple (standard filling) 6 Electrical connection 7 General control unit 8 Pushbutton 9 Inputs and outputs (CAN bus version) 0 CAN bus plug Pump bottom with control -05-EN

3 Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication KFG pump unit The KFG pump has three lubricant outlets for connecting up to three independent zones. A separate pump element is required for each outlet. Up to four pump elements with different delivery volumes are available so the delivery rate can be adjusted to the requirements of the individual zones. This provides all lubrication points with the required amount of lubricant during each lubrication cycle. The pump fill level can be monitored using the integrated rocker switch (W/WG for NLGI Grade greases). The pump is available in various voltage designs. An agitator driven by a geared motor ensures lubricant can be delivered at temperatures down to -5 C depending on the medium. This also applies to KFGS and KFGC (CAN bus) pump units. KFGS pump unit Pump units of the KFGS series are reservoir pump units with an integrated control unit based on the KFG. The KFGS pump unit is controlled by the IG50--I integrated control and monitoring unit, which can operate based on time or pulses and with or without a monitoring function. This control unit provides the following advantages: Non-volatile memory with PIN code protection Recording of remaining intervals and remaining lubrication times Recording of fault notifications (diagnostics memory, fault memory, not deletable) Data backup in case of voltage failure Connectivity for external pushbutton Connectivity for inductive piston detector Operation display system Fault indication system Interval time and contact time can be adjusted independently, including on monitored systems Easy electrical connection using plug connectors, all electrical options can be used via cable harness Interval times (timer) and pump cycle times (contact) can be entered via a display. An inductive piston detector is used to monitor the feeding operation on progressive systems. The KFGS pump unit is available in the same reservoir designs, reservoir sizes and voltage designs as the KFG series. KFGC (CAN bus) pump unit Pump units of the KFGC (CAN bus) series are pump units from the KFG series with an integrated CAN bus control unit. The LC-CAN5000 control units offer the following special features: CAN bus interface (SAE J99), which allows units to be seamlessly integrated into the CAN bus networks. The lubrication system can be monitored, operated and configured through the CAN bus. There is also the option of configuring and independently operating the pump unit via the IRDA interface. The control unit is still able to control up to four independent zones and to supply them from a single pump unit. To achieve this capability, electric switch valves which are controlled based on the parameters set for each individual lubrication zone are placed in the main line. The control unit has up to four solid-state switching outputs for this purpose. Aside from valve control, the outputs can also be configured as digital outputs for other purposes. In addition to the above-mentioned outputs, up to four digital inputs are available, e.g. for monitoring piston detectors, pressure switches or other switching contacts. -05-EN

4 Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication Design Lubricant reservoir R R Pump units of the KFG, KFGS and KFGC (CAN bus) series are characterized by their compact construction and are divided into the assemblies for pump housing, lubricant reservoir, control unit and fill level monitoring. A short description of the individual assemblies follows below. Pump housing The lubricant reservoir is available in kg, 6 kg and 0 kg sizes. The reservoirs are made of transparent plastic and have fill level markings that allow the fill level to be monitored visually. The pump fill level can be monitored using an integrated rocker switch or, optionally, a capacitive level switch attached to the cover. P A M x,5 P A The pump housing contains, among other things, the pump drive, control unit (KFGS) and three lubricant outlets for installing a maximum of three pump elements. A conical head nipple can optionally be attached to the pump housing via the alternative connections to fill the pump. A filler socket or grease return can also be attached. A display and control screen is mounted on the front side of the KFGS design, while the KFGC (CAN bus) design has a display attached. An IRDA interface is integrated into this screen, which can optionally be used to program the pump. Depending on the pump version and voltage design, the electrical connections are located on the left front and/or the underside of the pump housing. Pump element The pump element meters the lubricant then passes it to the downstream lubrication points or feeders. Four different pump elements with a delivery volume ranging from 0.8 to.5 cm /min. are available to provide the required quantity of lubricant. Pressure regulating valve Pressure regulating valve with optional lubricant nipple KFGS control unit Pump units of the KFGS series are equipped with an IG50--I integrated control unit with a control display. Parameters for interval times (timer), interval pulses (counter) and pump cycle times (contact) can be entered through the control unit. Assembly holes A mounting flange with assembly holes is present on the back of the pump housing on all pump versions. Alternative connections Assembly holes Ø ± 0. Pump element Pump element with pressure regulating valve Pressure regulating valve To protect the components of progressive systems from overpressure damage, a pressure regulating valve must be integrated into the pump element. If the operating pressure exceeds the cracking pressure of the pressure regulating valve, the valve opens and the lubricant flows back (on versions with a return line) into the lubricant reservoir. The pressure regulating valve is installed on the pump element. KFGS display and control screen KFGC (CAN bus) Pump units of the KFGC (CAN bus) series are equipped with an integrated CAN bus-capable control unit. All parameters that are relevant to the control and monitoring function can be integrated into higher-level control units. Parameters can be transmitted via the IRA interface if a CAN bus interface is unavailable. KFGC (CAN bus) display -05-EN

5 Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication Functional description of progressive system with KFG pump unit A general progressive feeder system consists of the following components: Pump unit with pump element and pressure regulating valve Lubricant lines Progressive feeders When the pump motor is turned on, the piston pump delivers lubricant from the lubricant reservoir to the lubricant outlet. The pump element attached to the outlet delivers the lubricant further, into the downstream main line. The lubricant flows through the main line to the progressive feeder. There, the lubricant is distributed according to the volume required by the lubrication point being supplied. In progressive systems with a master feeder and secondary feeder, the lubricant coming from the pump unit is delivered to the master feeder. The master feeder distributes the lubricant to the secondary feeders according to their individual volume requirements. From there, the lubricant flows to the lubrication points. Functional description of progressive system with KFGS pump unit The general functional description for progressive systems with a KFG pump unit also applies for the design with KFGS pump control. The control unit integrated into the pump housing allows the following additional configuration, monitoring and connectivity options: Interval time and contact time can be adjusted independently, including on monitored systems Recording of remaining intervals and remaining lubrication times Data backup in case of voltage failure Non-volatile memory with PIN code protection Connectivity for inductive piston detector to monitor the feeder functionconnectivity for external pushbutton Internal fill level monitoring (W control); lubrication cycle is halted and a fault signal is sent if the fill level falls below minimum Functional description of progressive system with KFGC (CAN bus) pump unit The general functional description for progressive systems with a KFGS pump unit also applies for the design with CAN bus pump control. The integrated LC-CAN5000 control unit permits the lubrication zone of a progressive feeder system to be distributed into individual lubrication zones for which individual parameters (e.g. contact and interval times) can be set. Up to four lubrication sections can be installed in total. To distribute the lubricant, a corresponding number of electric switch valves is installed in the lubricant line leading from the pump element. A valve is opened as soon as the control unit starts a pump cycle period for the corresponding lubrication segment. The pump can only provide one lubrication segment with adequate lubrication, so it must be ensured that only one valve is opened during operation. This is handled by the internal control unit in automatic and semiautomatic operation. A 5/ directional solenoid valve can optionally be used in place of single valves Example of progressive system with KFG pump unit Example of progressive system with KFGS pump unit Progressive system with KFG pump unit KFG unit Electrical pump connection Pump element with pressure regulating valve Lubricant line 5 Master feeder 6 Secondary feeder 7 Lubrication points KFGS progressive system with piston detector KFGS unit Power supply Fault indicator light Pump element with pressure regulating valve 5 Lubricant line 6 Master feeder 7 Piston detector 8 Secondary feeder 9 Lubrication points Progressive system with KFGC (CAN bus) pump unit -05-EN 5

6 Pump units of the KFG series for vehicle lubrication KFG pump unit Dimensions kg 6 kg 0 kg KFG pump unit, reservoir sizes kg, 6 kg and 0 kg max (Reservoir size 0 kg ) 7.5 (0 kg) 7 (6 kg) with W or WG 78.5 Max Max Min Ø (Reservoir size kg ) 7.5 (Reservoir size 6 kg ) ( kg) 8 in 05 with pressure relief valve Delivery data Pump element Delivery rate Maximum flow pressure Max. permis. pressure at pump element [cm /min.] [mbar with NLGI ] [bar] KFG.U KFG.U KFG.U KFG.U EN

7 Pump units of the KFG series for vehicle lubrication Fill level monitoring Fill level switch type: W Designed as rocker switch, for NLGI Grade greases Functional description The W/WG fill level switches described below are designed as rocker switches and are integrated in the bottom of the reservoir. A magnetic rocker mounted on the agitator is turned downward by the grease resistance when the reservoir is full and the agitator rotates. On the W version, a pulse is created at each revolution; in contrast, versions with signal smoothing (WG) keep a constant signal. When the minimum fill level is reached, the resistance the grease exerts on the rocker subsides. The rocker turns back and the pulse (W) or signal (WG) sequence is interrupted. Technical data for W fill level control Fill level monitoring Function...mechanical, via floating reed contact Form of contact...no-contact Switching capacity, max W Switching voltage, max... VDC Switched current, max....5 ma, only ohm load ) Plug-in connection...din EN 6097/IEC 97 Connection diagram...round plugs (seven pin) ) ) No inductive load, no lamp load (signal lamp) ) connectoin socket - see Accessoories page W block diagram W connector pin assignment (pump unit) PIN Description = - Supply voltage potential (0V, GND) = 5 + Supply voltage potential = not assigned = not assigned 5 = + Potential 6 = Signal (pulses) 7 = not assigned Signal Contact W closed, go position Contact W open Function Reservoir filled Reservoir empty Fill level switch type: WG Designed as rocker switch with signal smoothing, floating signal contact, for NLGI Grade greases Floating signal from fill level monitoring Fill level information can also be queried during the interval time. Reverse voltage protection in pump feed line planned. Optional time-out periods. The individual functions can be programmed according to the customer's requirements. Technical data for WG fill level control Fill level monitoring Function...floating contact Form of contact...changeover Switching capacity...max. 60 W Switching voltage...max. 0 VDC Plug-in connection...din EN 6097/IEC 97 Connection diagram...round plugs (seven pin) ) ) connectoin socket - see Accessoories page WG connector pin assignment (pump unit) PIN Description = - Supply voltage potential (0V, GND) = 5 + supply voltage potential = nc (pin 5 and pin closed, reservoir empty = no (pin 5 and pin closed, reservoir filled) 5 = COM (+ potential) 6/7 = not assigned -05-EN 7

8 Pump units of the KFG series for vehicle lubrication Pressure regulating valves for progressive systems R R Pressure regulating valve without lubricant nipple Spare parts P M x,5 P A Tube Ø Cracking pressure Order No. [mm] [bar] A Technical data Cracking pressure / 00 ± 0 bar Nominal tube sizes Ø. 6 mm, 8 mm, 0 mm Pressure regulating valve with lubricant nipple A P R Connections for pressure regulating valve Connection to main lubricant line Pipe thread for pump element Grease emitted at overpressure Note The pressure regulating valve is optionally available with a lubricant nipple with T connector output (see accessories on page ). Pump elements Delivery rate: 0.8,.,.8,.5 cm /min. ) Technical data Delivery rate ) Number of [cm /min.] grooves Spare parts Order No. Max. permiss. operating pressure: 0.8,.,.8,.5 cm /min bar ) The values given here apply for a temperature of 0 C, back pressure of 50 bar and greases of NLGI Grade. For progressive systems, pump elements.5 cm / min. are recommended..5 KFG.U.8 KFG.U. KFG.U 0.8 KFG.U 8-05-EN

9 Pump units of the KFG series for vehicle lubrication General conditions for electrical connections Power supply / VDC Connector pin assignment for / VDC M - + X KFG...DC Cable socket in accordance with DIN EN Pin Description - (mass) = M - () potential (0 V, GND) + (current) = L+ Supply voltage potential (5) (Main machine switch ON) AT L+ L- General conditions for electrical connections Nominal Power Power Pump Max. voltage consumption consumption starting current pre-connected fuse [load-dependent] [max.] [~0 ms] VDC ).5 A ) <.5 A.5 A A ) ) VDC ). A ) < 5 A 9 A 6 A ) ) ) Protective measures that must be applied for designated usage: "Functional Extra Low Voltage", "Protective Extra Low Voltage (PELV) Standards: EN 600 Part : IEC 600-: DIN VDE 000 Part 0 / IEC 6- -: HD8.. ) Typical value at ambient temperature = 5 C and operating pressure = 50 bar ) Fuse in accordance with DIN 758 T. ) Conductor: cross-section.5 mm, length m -05-EN 9

10 Pump units of the KFGS series for vehicle lubrication KFGS pump unit with integrated control Dimensions kg 6 kg 0 kg KFGS pump unit, reservoir sizes kg, 6 kg and 0 kg ax ax n Ø (Reservoir size 6 Kg ) 8 (Reservoir size Kg ) 66 (Reservoir size 0 Kg ) ( 0 Kg ) 7 ( 6 Kg ) 06 ( Kg ) Z 5.5 n with pump element and W control 05 with pressure relief valve Delivery data Pump element Delivery rate Maximum flow pressure Max. permis. pressure at pump element [cm /min.] [mbar with NLGI ] [bar] KFG.U KFG.U KFG.U KFG.U EN

11 Pump units of the KFGS series for vehicle lubrication IG50--I integrated control and monitoring unit The KFGS pump unit is controlled by the IG50--I integrated control and monitoring unit. Display General The IG50-I control and monitoring device is an integral component of the KFGS pump unit. Its functions are specially designed to control and monitor centralized lubrication systems. The customer can program the control unit to adapt it to the particular operating conditions of the machine/system. Pause (tpa) in "TIMER" mode The interval (time period between two lubrications) in the TIMER mode is determined based on a time interval generated by the control unit and the value programmed as the tpa. Its value can be set from 0. h to 99.9 h. Pause (cpa) in "COUNTER" mode The interval (time period between two lubrications) in "COUNTER" mode is determined based on the time between pulses received at connection DK (signal change from 0 V to V) and by the value programmed as the cpa. Its value can be set from to 999 pulses. In this mode, the DK connection (pin, blue cable core) leading from the unit is used as a clock pulse input to trigger lubrications after a specified number of pulses. In this case, an external pushbutton cannot be used to trigger interim lubrications. Setting interval and pump cycle times and desired monitoring function See the operating instructions included with the pump unit for information on how to configure the control unit for application-specific values and functions. Function: (Standard "TIMER" function without monitoring) The lubrication intervals are repeated cyclically according to the set interval (tpa or cpa). The pump cycle time during a lubrication procedure corresponds to the time configured on the control panel as tco (contact time) in minutes.interval and pump cycle times advance only in the presence of supply voltage (attach connection 5 and to V DC or V DC depending on unit). When the supply voltage is turned off (power supply is interrupted), the current interval time is saved and continued once the supply voltage is turned on again. When the monitoring function CS is programmed (only for centralized lubrication systems with cycle switch), the piston detector mounted on a progressive feeder is queried for a signal during the pump cycle time. If this signal is absent during the preselected pump cycle time (tco), a monitoring program (block operation) is started after the cycle time finishes. During this program sequence, the pump unit is turned on up to two times at specially defined intervals and the piston detector is monitored for a signal. If the piston detector signal reaches the control unit, the monitoring program ends immediately and operation continues as normal. If the monitoring program completes its sequence, a fault signal is sent on completion and the operational sequence is halted. While the monitoring program is ongoing, no interim lubrications can be triggered. Storage (EEPROM) The control unit has non-volatile memory (EEPROM), so continuous power supply is not required to store intervals and fault notifications. When the supply voltage is turned off, the current value is saved and will be available for continued operation once the supply voltage is re-established. Monitoring and fault indications Function monitoring with piston detector or pressure switch Progressive systems can be monitored by a piston detector and single-line systems can be monitored by a pressure switch. To do this, monitoring under COP must be configured as CS (cycle switch, piston detector) or PS (pressure switch) when the device is configured (programmed). The signal from the switch is then monitored during lubrication. If the signal is not sent during the lubrication procedure and the monitoring program it automatically triggers does not start, a fault signal is sent (connection SL is constantly switched on) after the monitoring program ends, and the operational sequence is interrupted. When monitoring is performed by a pressure switch (PS), any fault signal is sent directly after conclusion of the monitoring time. In contrast with the CS setting, there is no monitoring program (block operation) in this case. The error codes FCS (Fault Cycle Switch) and FLL (Fault Low Level) can be viewed by pressing a key on the control panel. -05-EN

12 Pump units of the KFGS series for vehicle lubrication Fill level monitoring Fill level switch type: W Designed as energized rocker switch, for NLGI Grade greases Contact W closed, go position Contact W open Functional description The W fill level switch described below is designed as a rocker switch and is integrated in the bottom of the reservoir. A magnetic rocker mounted on the agitator is turned downward by the grease resistance when the reservoir is full and the agitator rotates. A pulse is created at each revolution of the agitator. When the minimum fill level is reached, the resistance the grease exerts on the rocker subsides. The rocker turns back and the pulses are interrupted. In contrast to the KFG pump unit, on which the fill level signal is evaluated externally, the internal pump control unit on the KFGS pump unit evaluates the fill level of the W control. A fault indicator light can optionally be connected through the 7-pin plug on the bottom of the pump (see connectivity on page /5). Pressure regulating valves for progressive systems R R Pressure regulating valve without lubricant nipple Spare parts P Tube Ø [mm] Cracking pressure Order No. [bar] A M x,5 P A Technical data Cracking pressure / 00 ± 0 bar Nominal tube sizes Ø. 6 mm, 8 mm, 0 mm A P R Connections for pressure regulating valve Connection to main lubricant line Pipe thread for pump element Grease emitted at overpressure Pressure regulating valve with lubricant nipple Note The pressure regulating valve is optionally available with a lubricant nipple with T connector output (see accessories on page ). -05-EN

13 Pump units of the KFGS series for vehicle lubrication Pump elements Delivery rate: 0.8,.,.8,.5 cm /min. ) Technical data Delivery rate ) Number of [cm /min.] grooves Spare parts Order No. Max. permiss. operating pressure: 0.8,.,.8,.5 cm /min bar.5 KFG.U.8 KFG.U. KFG.U 0.8 KFG.U General conditions for electrical connections ) The values given here apply for a temperature of 0 C, back pressure of 50 bar and greases of NLGI Grade. For progressive systems, pump elements.5 cm /min. are recommended. 7-pin cable socket for and VDC power supply Connector pin assignment Pin Color code Conductor coloring...bn...brown...rd-bk...red-black...bu...blue...pk...pink 5...BK...black 6...BK...black 7...VT-GN...purple-green Description Accessories Order No. Cable harness, m long, in corrugated pipe, with pump-side socket Cable harness, three-core, 8 m long, in corrugated pipe, with pump-side socket Note The connector pin assignment depends on the specific operating mode. The pins should therefore be assigned according to the following examples. General conditions for electrical connections Nominal Power Power Pump Max. voltage consumption consumption starting current pre-connected fuse [load-dependent] [max.] [~0 ms] VDC ).5 A ) <.5 A.5 A A ) ) VDC ). A ) < 5 A 9 A 6 A ) ) ) Protective measures that must be applied for designated usage: "Functional Extra Low Voltage", "Protective Extra Low Voltage (PELV) Standards: EN 600 Part : IEC 600-: DIN VDE 000 Part 0 / IEC 6- -: HD8.. ) Typical value at ambient temperature = 5 C and operating pressure = 50 bar ) Fuse in accordance with DIN 758 T. ) Conductor: cross-section.5 mm, length m -05-EN

14 Pump units of the KFGS series for vehicle lubrication Settings for progressive lubrication Control using pulses (Counter mode = pulse-dependent lubrication) The duration of the interval time is determined by a pulse generator that sends pulses to the control unit based on how long the vehicle has been in use. The control unit counts the pulses that are received and starts the pump after the preset number of pulses. The pump cycle time is defined by a time value. Both the number of pulses that determine the interval time and the pump cycle time can be configured. The fill level monitoring unit is internally connected to the integrated pump control unit. A fault signal can be sent to the vehicle control/ electronics system via indicator light SL. Connectivity for counter operation without system monitoring Interval depends on number of pulses Pump cycle time depends on time Connectivity for counter operation without system monitoring Connectivity for counter operation with system monitoring KFGS... KFGS... KFGS... X X X BN RD-BK BU BN RD-BK BU PK BN RD-BK BU PK BK BK F F DK SL, W F DK SL, W ZS 5 5 (Example: of a stop light switch) (Observe the starting current of the pump!) 5 5 Connector pin assignment PIN Code Assignment - Supply voltage potential (0 V, GND) 5 + Supply voltage potential + Potential of stop light switch signal Connector pin assignment in counter operation PIN Code Assignment - Supply voltage potential (0 V, GND) 5 + Supply voltage potential "ignition ON" DK Pushbutton "st Interim lubrication", "nd Delete fault notification" SL Indicator light "fault" 5 ZS piston detector "+" 6 ZS Piston detector "signal" -05-EN

15 Pump units of the KFGS series for vehicle lubrication In timer mode, the interval time is determined by a time value. It is configured by entering a time value in minutes and/or hours. The pump cycle time is configured using a time value in hours, minutes and seconds. The fill level monitoring unit (W control) is internally connected to the integrated pump control unit. A fault signal can be sent to the vehicle control/electronics system via indicator light SL. Connectivity for timer operation without system monitoring Connectivity for timer operation with system monitoring KFGS... KFGS... X X BN RD-BK BU PK VT-GN BN RD-BK BU PK BK BK VT-GN F DK SL, W SL, W F DK SL, W PS + SL, W 5 5 Connector pin assignment in timer operation PIN Code Assignment - Supply voltage potential (0 V, GND) 5 + Supply voltage potential "ignition ON" DK Pushbutton "st Interim lubrication", "nd Delete fault notification" SL Indicator light "fault" 5 PS Pressure switch "+" 6 PS Pressure switch "signal" 7 SL Indicator light "pump ON" Description Order No. Cable harness, in corrugated pipe, with pump-side socket Accessories 8 m length m length m length EN 5

16 Pump units of the KFGC (CAN bus) series for vehicle lubrication KFGC (CAN bus) pump unit with integrated control Dimensions kg 6 kg 0 kg KFGC (CAN bus) pump unit, reservoir sizes kg, 6 kg and 0 kg Ø ( Reservoir size Kg ) 9.5 ( Reservoir size 6 Kg ) 66 (Reservoir size 0 Kg ) ( 0 Kg ) 7 ( 6 Kg ) 06 ( Kg ) Delivery data Pump element Delivery rate Maximum flow pressure Max. permis. pressure at pump element [cm /min.] [mbar with NLGI ] [bar] KFG.U KFG.U KFG.U KFG.U EN

17 Pump units of the KFGC (CAN bus) series for vehicle lubrication LC-CAN5000 integrated CAN bus control unit with display Pump units of the KFGC (CAN bus) series are reservoir pump units (piston pumps) with an integrated control unit for on-demand lubricant supply to centralized lubrication systems with progressive feeders or to single-line systems. A special feature of pump units of the KFGC (CAN bus) series is the integrated LC-CAN5000 control unit, which is distinguished by the following characteristics: CAN bus interface (SAE J99), which allows units to be integrated into the CAN bus networks of machines and systems. The lubrication system is monitored, operated and configured through the CAN bus by the vehicle electronic control system. There is also the option of configuring and operating the pump unit without a CAN bus connection. The control unit is able to control and monitor up to four independent zones and to supply them from a single pump unit. Electric switch valves which are controlled based on the parameters set for each individual lubrication zone are placed in the main line. The control unit has up to four solid-state switching outputs for this purpose. The control unit's comprehensive monitoring functions allow potential faults to be detected early. This includes, among other things, monitoring the fill level in the lubricant reservoir, monitoring the signal lines on attached components for line breakage, and monitoring the switching outputs for short circuits. Important system events such as a low fill level in the lubricant reservoir are saved by the control unit and given a time stamp. This allows the causes of operational faults to be determined more easily. The flexible parameters and configuration options allow custom lubrication concepts to be implemented for each individual lubrication zone in the system. The control unit can store up to 6 sets of parameters. Each set of parameters contains all the information required to control and monitor the lubrication process. This means that different lubrication scenarios can be prepared and saved then called on when needed. The CAN bus control unit is available in / V DC designs. Aside from valve control, the outputs can also be configured as digital outputs for other purposes. In addition to the outputs, up to four digital inputs are available, e.g. for monitoring piston detectors, pressure switches or other switching contacts.a detailed description of the electrical connections can be found in the operating instructions for the KFG series of pumps. -05-EN 7

18 5 Pump units of the KFGC (CAN bus) series for vehicle lubrication Connections Connectivity Example of connecting four reversing valves and four piston detectors on devices with the maximum equipment level (6x Mx round plug-in connections) for operating a progressive feeder system, distributed in four lubrication zones 6 7 C A B Assignment of round 7-pin plug Assignment of CAN bus plug Assignment of Mx -pin round plug CS CS CS V V V B X BN RD-BK BU PK BK BK VT-GN A B C CAN-BUS Mx Mx Mx Mx Mx Mx 6 7 C A Power supply through 7-pin round plug CAN bus connection, plug type DEUTSCH DT0-P-L0 5 F S CS (MC) Mx V SL RD CS Mx CS Mx CS Mx V V V 0 M L+ CS.. = Piston detector V.. = Reversing valves Connection for reversing valve/piston detector (max. 6 connections) Legend for connection illustration with maximum equipment level S CS Piston detector - V V Valves MC L+ Machine contact + potential of supply voltage SL Indicator light "fault" (can alternately be operated in place of valve (V)) F Fuse S Ignition switch General conditions for electrical connections The general conditions for electrical connections are identical with those of the KFG and KFGS series. The data listed below are specific to CAN bus units. KFGC (CAN bus), general conditions for electrical connections Switching outputs: Type: Solid-state output, short-circuit-proof and overload-proof Max. current-carrying capacity: - with simultaneous operation of outputs.0 A - with simultaneous operation of outputs.5 A - with operation of output.5 A Modes of operation: - Single operation - Parallel connection of multiple outputs while simultaneously increasing output current Signal inputs: Type: digital solid-state input, short-circuit-proof Connectivity: - Switching contact, no detection of wire breakage - Dual wire sensors (e.g. piston detector), detection of wire breakage 8-05-EN

19 Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication Accessories KFG - IG50--E electronic control unit Technical data Control voltage )... or V DC Max. contact rating, connection M...0 A SL output... W Protection class )...IP 0, DIN 0050 Temperature range...-5 to +75 C Fusing max....5 A Programmable interval times to 99.9 h Programmable pump cycle time to 99.9 min. Programmable pulses... to 999 Operation and fault hours memory... 0 to h Technical description...see following page ) Specify control voltage when ordering. ) Ensured both in vertical (connector pointing downward) and horizontal installation. IG50-E Normal operational sequence 0±. (Time axis not to scale) Legend for operational sequence tu = Ignition cut-off ts = Contact time tp = Interval time 0 = Battery + / vehicle electrical system 5 = Operating voltage + / "ON" after ignition = Operating voltage DK/MK = Pushbutton / interim lubrication or pulse counter input PS/CS = Pressure switch / cycle switch M = Pump motor SL = Signal lamp Z = Ignition lock F = Fuse 5 A Cable set for IG50--E control unit Description KFG control unit and cable set Order No. Note Tab connectors are loose. RD/BK = Ignition, terminal 5 Electronic control unit IG50--E BN = Mass Cable set PK = Indicator lamp,.5 m (optional) BU = Pushbutton/machine contact Contact assignments on connector plug of IG50--E control unit -05-EN 9

20 Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication IG50--E electronic control unit Control and display elements IG50 control units have a control and display panel that allows set parameters and the programmed functions to be checked, monitored and readjusted as necessary. Modes of operation PAUSE (pump OFF) with timer function programmable from 0. to 99.9 h Digital display by selecting: tpa (t = Timer, PA = PAUSE)The PAUSE (time period between two lubrication cycles) is determined based on a time interval generated by the control unit and the value (in hours) programmed as the PAUSE (tpa). PAUSE (pump OFF) with counter function programmable from to 999 pulses Digital display by selecting: cpa (c = Counter, PA = PAUSE) The PAUSE (time period between two lubrication cycles) is determined based on the time between signals received by the clock pulse unit and the value programmed as the PAUSE (cpa) CONTACT (pump ON)) with timer function Programmable from to 99.9 minute(s) Digital display by selecting: tco (t = Timer, CO = CONTACT) The pump cycle time (CONTACT) is determined based on the time interval generated by the control unit (timer) and the value programmed (in minutes) for CONTACT (tco). Monitoring functions CS (Cycle Switch) This monitoring function is designed for centralized grease lubrication systems with progressive feeders whose piston movement is monitored by a cycle switch. If the monitoring parameter CS is programmed, the cycle switch mounted on the progressive feeder monitors for the relevant signal during pump operation. The selected monitoring parameter (PS or CS) is shown by the corresponding LED in PAUSE mode. Without monitoring (OFF) Monitoring can also be switched off (OFF). The PS or CS LEDs do not light up. Fault notifications A centralized fault is indicated by the red LED labeled "FAULT" lighting up and remaining constant. The cause of the fault notification is also shown on the digital display to assist in fault-finding. The following notifications are provided: FPS Pressure build-up fault on pressure switch monitoring. FCS Cycle switch fault in case of blocked or non-functional progressive feeder (line break). Special functions The IG50 series of control units possess two electronic counters which store times permanently and in a way that users cannot alter. These counters provide operational control of the centralized lubrication system and are shown on the LED display. Fault-hours counter The fault-hours counter adds up the time of long-term faults. The counter's record is automatically updated and cannot be deleted. The current counter reading can be shown on the display and control panel by calling up the function parameter Fh. The current value is shown in hours. The counter increments in 0. hour steps, i.e. the smallest interval it can display is 6 minutes. Operational hours counter The electronic operational hours counter adds up the time during which the operating voltage is applied to the control unit. The counter's record is automatically updated and cannot be deleted. The current counter reading can be shown on the display and control panel by calling up the function parameter Oh. The current value is shown in hours. The counter increments in 0. hour steps, i.e. the smallest interval it can display is 6 minutes. The units meet the statutory requirements of EG Directives 7/5/EEC as amended by 95/5 EC 89/6/EEC Application The IG50--E universal control unit is used to control and monitor centralized lubrication systems on commercial vehicles. The control unit's functions can be programmed. Its housing dimensions, electrical connection and functions are compatible to previous VOGEL control units. The control elements have a film that protects them from humidity and contamination. The unit possesses non-volatile data memory which is used to store configuration data and parameters. This allows the control unit to function without a continuous power supply. If an external SL signal lamp has been installed in the vehicle cab, it will light up seconds after the unit is switched on. Assembly The unit is to be installed inside a closed area in the vehicle where it is protected from environmental influences. It is fastened using assembly brackets. The IG50--E is contained in a housing that meets protection class IP 0. The plug meets safety class IP 00. If the control unit is installed in a location that is difficult to access, we recommend also using an illuminated pushbotton on the dashboard for fault notification and function control EN

21 Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication Pressure regulating valves with T connector output for progressive systems R R Pressure regulating valve Pressure regulating valve with T connector output P A Tube Ø [mm] Cracking pressure Order number [bar] M x,5 P A Technical Data Cracking pressure ± 0 bar Nominal tube sizes Ø... 6, 8, 0 mm Pressure gauge 6.5mm (max. 8) Ø 6mm 0 mm Indicating range Pressure gauge Order no. 5 mm (max. 5) G / 0 to 50 bar 0 to 600 psi to 00 bar Washer ) ) Washer must be ordered separately for each pressure gauge. Connecting piece for pressure gauge Connecting piece for pressure gauge d Order no. M0x 0- Mx Pressure gauge screw connection with gasket G/ G/ Ø 6 mm for pipeø 0 mm Pressure gauge screw connection Pos. Order no EN

22 Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication Special equipment and accessories Filling cylinder with connecting piece Filling cylinder/screw unions Filling cylinder with screw union 50 mm Item Description Order no. SW M0x.5 Ø 56 mm M0x.5 M0x.5 Filling cylinder complete Long filler socket Connecting piece for filler socket Banjo fitting to change the filling position Filling device with quick-action coupling Filling device with quick-action coupling Filling device - quick-action coupling G / Item Description Order no. Washer DIN 760-Ax8 CU Filler sockets ø 8.6 mm G / SW9 d ø 8 mm Coupling socket (for refill connection) Hose fitting for connection to to coupling socket Diameter (d) Diameter (d) Topping-up pumps Topping-up pump ) Technical Data Topping-up pumps Delivery rate...~ 0 cm /stroke Description Order no. ) Note A generic pump is depicted; the actual pumps may differ in appearance. with gear, for 5 kg drum for 50 kg drum without gearfor 5 kg drum corresponding filler socket EN

23 Pump units of the KFG, KFGS and KFGC (CAN bus) series for vehicle lubrication Explanation of order codes Example: KFG S - 5 W / X A X / VDC Pump unit Control unit without marking=without control S = with control and monitoring ) C = in CAN bus design / V DC ) Reservoir capacity = kg = 6 kg 5 = 0 kg Pump housing design 5 = version number Type of fill level monitoring X = without W = switching point, minimum, designed as reed contact (NLGI grease) WG = switching point minimum with signal smoothing (NLGI grease) Pump element position Pump element position Pump element position Example: KFG pump unit (KFG) with internal control (S) with lubricant reservoir size of kg (), pump housing design (5) with switching point for minimum fill level monitoring, designed as reed contact with rocker (W), with additional pressure regulating valve (M), with a.5cm /min. pump element installed at position (XAX), without tube connection (/), for use in vehicles (000) with operating voltage of V AC and protection class IP55 (VDC) gives the order number: KFGS-5WMXAX/000-VDC Pressure regulating and relief valve / = without M = with pressure regulating valve for multiple-line and progressive systems, 00 bar version, pivoted N = with pressure regulating valve for multiple-line and progressive systems, customer-specific ) Delivery rate of pump elements and their layout X = without A =.5 cm /min. (-groove) B =.8 cm /min. (-groove) C =. cm /min. (-groove) D = 0.8 cm /min. (-groove) Layout of pump elements Example of installed pump elements Code installed pump elements AAA = and and AXA = and AXX = Tube connection / = without A = Ø 6 mm B = Ø 8 mm C = Ø 0 mm Version key 000 = Basic design for use in vehicles Motor key data VDC = Operating voltage V DC, protection class IP 55 VDC = Operating voltage V DC, protection class IP 55 Customer-specific requirements/accessories ) Notify us of the setting times for the control unit. ) System is designed according to customer's specifications. ) On a design with a pressure regulating valve, its cracking pressure and tube diameter are to be specified (see pages 8 and ). -05-EN

24 Order No. -05-EN Subject to change without notice! (07/009) Important product usage information All products from SKF may be used only for their intended purpose as described in this brochure and in any instructions. If operating instructions are supplied with the products, they must be read and followed. Not all lubricants are suitable for use in centralized lubrication systems. SKF does offer an inspection service to test customer supplied lubricant to determine if it can be used in a centralized system. SKF lubrication systems or their components are not approved for use with gases, liquefied gases, pressurized gases in solution and fluids with a vapor pressure exceeding normal atmospheric pressure (0 mbars) by more than 0.5 bar at their maximum permissible temperature. Hazardous materials of any kind, especially the materials classified as hazardous by European Community Directive EC 67/58/EEC, Article, Par., may only be used to fill SKF centralized lubrication systems and components and delivered and/or distributed with the same after consulting with and receiving written approval from SKF. Further brochures US -90-US -00-US US -0-US US Operating Instructions for KFG/KFGS/KFGC (CAN bus) for use in vehicles Progressive systems for commercial vehicles Reservoir pump units of the KFG series for industrial use Operating Instructions for KFG/KFGS/KFGC (CAN bus) for industrial use Reservoir pump units of the KFG series for rotary application Operating Instructions for KFG/KFGS/KFGC (CAN bus) for rotary application SKF Lubrication Systems Germany AG. Industriestrasse Hockenheim Germany Tel. +9 (0) Fax +9 (0) This brochure was presented by: SKF is a registered trademark of the SKF Group. SKF Group 009 The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein.