SKF Electro-pneumatic Barrel Pump EPB-Pump- STA (Original operating and maintenance instructions according to EU Directive 2006/42/EC)

Transcription

1 SKF Electro-pneumatic Barrel Pump EPB-Pump- STA (Original operating and maintenance instructions according to EU Directive 2006/42/EC) REPBSTA1BFI.doc 2 May 2013 Rev. 1B

2 CONTENTS 1 EC Declaration of incorporation General description Design Operation Start-up Start-up in a central lubrication system Start-up as a feed or filler pump Replacing the lubricant drum Lubricant drum replacement in a central lubrication system Lubricant drum replacement as a feed or filler pump Regular inspections Fault isolation Fault isolation LED signals Troubleshooting table Technical data Designations Connections Electrical and pneumatic connections to SKF pumping centres SKF Maxilube, delivered after 1 April SKF Maxilube/IF-105 pumping centre, delivered prior to 1 April SKF Maxilube hydraulic unit 24V, delivered prior to 1 April SG-2102 hydraulic unit Spare parts Contact information REPBSTA1BFI.doc 2 May 2013 Rev. 1B

3 1 EC Declaration of incorporation Original declaration of incorporation for partly completed machinery (Machinery Directive 2006/42/EC, Annex II, part 1, section B) Oy SKF Ab Teollisuustie 6 (P.O. Box 80) FI MUURAME Persons authorised to compile the relevant technical documentation: Technical Manager and Product Manager, Centralized Lubrication Systems, Muurame Unit. Declares that in the case of the partly completed machinery: SKF Electro-pneumatic Barrel Pump SKF-EPB-PUMP-X/X-XXX the following essential requirements of the Machine Directive 2006/42/EC are applied and fulfilled: , 1.1.5, 1.1.6, 1.2.1, 1.2.2, 1.2.3, 1.2.4, 1.2.6, 1.3.1, 1.3.2, 1.3.4, 1.3.7, 1.5.1, 1.5.4, 1.5.6, 1.5.7, , 1.6.1, 1.6.2, 1.6.3, 1.6.4, 1.7.1, 1.7.2, 1.7.3, the relevant technical documentation is compiled in accordance with part B of Annex VII of the Machine Directive and that this documentation or parts hereof will be transmitted by post or electronically in response to a reasoned request by the national authorities and that this partly completed machinery conforms to the provisions of the following EC directives: EMC directive 2004/108/EC and furthermore declares that the following European harmonised standards have been applied: Machine directive 2006/42/EC: EN ISO /A1, EN ISO /A1 EMC directive 2004/108/EC: EN :2007 (for emissions), EN :2005 (for immunity) This partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of the Machine Directive 2006/42/EC. Muurame 14 December 2012 Place Date Tuomo Helminen Local Manager 1 (39)

4 Warning Read and follow the safety precautions and general instructions in this manual and also in the SKF manual Safety and general instructions for lubrication systems. Failure to follow these instructions could result in serious injury or damage to the lubrication system or the equipment that is lubricated. 2 General description SKF-EPB-PUMP-STA is an electro-pneumatic barrel pump, in which the traditional mechanical valve control has been replaced with electronic control. The main purpose of the pump is to feed lubricant into a central lubrication system. The pump can also be used as a separate feed or filler pump. In such a case, it must be connected to a separate 24 V power supply and a compressed air supply. The unit is fixed on the lubricant drum and locked on the drum nut. A fully-assembled pump system consists of a pump, a lid set and a compressed air regulator/oiler assembly. A separate installation kit is needed for installing the pump in an existing system. The kit contains components for attaching existing pneumatic and electric connections to the EPB pump. Note The SKF-EPB-PUMP-STA is intended for use with STA lid sets, which are suitable for greases in NLGI grades 0, 1 and 2. 3 Design Position Description 1 Inductive sensor 2 LED signal 3 Circuit board 4 Pneumatic valve 5 Inductive sensor 6 M12 connector Figure 1 SKF-EPB-PUMP-STA barrel pump 2 (39)

5 Position Description 7 Low level switch 8 Drum lid 9 Follower plate 10 Tank hose 11 Compressed air hose 12 M12 cable (L = mm) 13 Pressure hose 14 Grease filter 15 Bleed screw 16 M12 Y piece 17 M12 cable (L = 600 mm) Figure 2 MAX-LIDSET-XXX-STA-EPBP lid set Position Description 18 Shut-off valve 19 Pressure regulator 20 Pressure gauge Figure 3 MAXILUBE-SET-STA-EPBP compressed air regulator/oiler assembly 3 (39)

6 Figure 4 STA-EPBP installation kit Position Description 12 M12 cable (L = mm) 16 M12 Y piece 17 M12 cable (L = 600 mm) 21 Drum nut G2 STA 22 Air supply hose for the pump 23 Stopper 24 Compressed air distributor 25 M12 connector (selfassembled) 26 Set screw Stopper ( Figure 14, page 24) Wire set ( Figure 18, page 26) Installation kit SG-2102 ( Figure 30, page 35) 4 (39)

7 4 Operation The pump is operational when the power supply is connected and the green LED light is lit. The pump s operation is controlled by an internal circuit board. Signals sent by inductive sensors regulate the pneumatic valve. The sensors identify the piston s direction of movement. The lid set contains a low level alarm. The pump must be connected to a compressed air supply and a 24 VDC power supply. If the pump is incorporated in a central lubrication system, power is fed to the hydraulic unit through the M12 connector, either from the pump s own control unit or from an external control unit. The pump can also be used as a separate feed or filler pump. In such a case, it must be connected to a separate compressed air supply and a 24 V power supply through the M12 connector. See section 5.2: Connections ( page 19). Wear protective eyewear Wear hearing protection Read operating instructions Figure 5 Warning symbols on SKF-EPB-PUMP-STA pump 5 (39)

8 4.1 Start-up Start-up in a central lubrication system Warning Only professional electricians are allowed to make electrical connections. To minimise the risk of electric shock, check that the pumping centre is turned off before making any connections. All power must be disconnected before any work involving handling any conductive parts or opening any part of the system or product. Warning Make sure that there is no residual pressure in the system. Before opening the grease filter, remove pressure by opening the bleed screw (15) in the filter plug. Turn off the air supply by lifting up the shut-off valve button (18) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20). Detach the M12 cable (12) from the pump. If the system is under pressure when the components are being disconnected or opened, the components or lubricant might be flung in the air causing injury to people or damage to the environment. Note Check that the workspace is clean. Make sure that no impurities enter the pump, the follower plate or the lubricant drum. Impurities may cause damage to the lubrication system or the machine or device it lubricates. Note The numbers in brackets indicate position numbers in Figures 1, 2 and 3 ( pages 2 and 3). 1 Check the condition of the lubricant drum. Damage in the drum will prevent the follower plate (9) from lowering. 2 Remove the drum s original lid and press the follower plate closely on top of the lubricant in the drum. Ensure that air is pushed out from below the follower plate and that the follower plate s suction port starts to fill with lubricant. 3 Fasten the body (10) of the low level switch to the Ø 20 mm hole on the barrel lid. 4 Fasten the lid (8) onto the lubricant drum with wing screws. 5 Place the pump through the drum lid and follower plate to the barrel. Lock the pump with the set screw in the drum nut so that the lower part of the pump is approximately 2 cm above the bottom of the drum. 6 Connect the pump to a power supply through the M12 connector (6). See sections 5.2: Connections ( page 19) and 5.3. Electrical connections to SKF pumping centres ( page 21). If installed in other centres, verify the connections from the centre s electrical drawings. 7 Connect the compressed air hose (11) to the pressure regulator (19) and to the pump s inlet A. 8 Connect the low level switch cable (11) and the cables of the channel pressure control units and shut-off valves to the pumping centre as described in the electrical drawings. 9 Place the rod of low level switch (12) on top of the follower plate through the hole on the lid. 10 Using the pressure regulator (19) and the pressure gauge (20), set air pressure to (39)

9 bar. 11 Connect the tank hose (10) to the pump s pressure connection (P), and the other end of the hose to the grease filter (14). 12 Turn on the pump from the control or pumping centre. 13 Bleed the tank hose of air by opening the bleed screw (15) of the grease filter. 14 Stop the pump from the control or pumping centre. 7 (39)

10 15 Move the tank hose to the pump s tank connection (T), and the other end of the hose to the pumping centre s tank connection (T). Before attaching the hose, make sure that there is no air coming out of the hose, only grease. 16 Connect the pressure hose (13) to the pump s pressure connection (P) and the other end of the hose to the grease filter (14). 17 Turn on the pump from the control or pumping centre. 18 Bleed the pressure hose of air by opening the bleed screw (15) of the grease filter. 19 Stop the pump from the control or pumping centre. 20 Fill the header piping with lubricant by turning on the pump from the control or pumping centre. 21 After the header piping is filled and bled of air, turn off the pump. 22 Check the header piping for leaks by applying pressure on it. Make sure that the pressure is suitable for the materials used in the current system and piping. 23 Using the pressure regulator (19) and the pressure gauge (20), set the air pressure of the pumping centre to bar. At this pressure, the pump feeds lubricant through its pressure port P at a pressure of bar ( psi / MPa) Start-up as a feed or filler pump Warning Only professional electricians are allowed to make electrical connections. All power must be disconnected before any work involving handling any conductive parts or opening any part of the system or product. Warning Make sure that there is no residual pressure in the system. Before opening the grease filter, remove pressure by opening the bleed screw (15) in the filter plug. Turn off the air supply by lifting up the shut-off valve button (18) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20). Detach the M12 cable (12) from the pump. If the system is under pressure when the components are being disconnected or opened, the components or lubricant might be flung in the air causing injury to people or damage to the environment. Note The tank connection (T) and the tank hose (10) are not usually used when the pump is used as a feed or filler pump. In this mode, the pump requires a separate power supply (24 VDC / min 0.2 A, for example: SKF code ). Note Check that the workspace is clean. Make sure that no impurities enter the pump, the follower plate or the lubricant drum. Impurities may cause damage to the lubrication system or the machine or device it lubricates. Note The numbers in brackets indicate position numbers in Figures 1, 2 and 3 ( pages 2 and 3). 8 (39)

11 1 Check the condition of the lubricant drum. Damage in the drum will prevent the follower plate (9) from lowering. 2 Remove the drum s original lid and press the follower plate closely on top of the lubricant in the drum. Ensure that air is pushed out from below the follower plate and that the follower plate s suction port starts to fill with lubricant. 3 Fasten the body (10) of the low level switch to the Ø 20 mm hole on the barrel lid. 4 Fasten the lid (8) onto the lubricant drum with wing screws. 5 Place the pump through the drum lid and follower plate to the barrel. Lock the pump with the set screw in the drum nut so that the lower part of the pump is approximately 2 cm above the bottom of the drum. 6 Connect the pump to a power supply through the M12 connector (6). See section 5.2: Connections ( page 19). 7 Connect the compressed air hose (11) to the pressure regulator (19) and to the pump s inlet A. 8 Connect the low level switch cable (11) and the cables of the channel pressure control units and shut-off valves to the pumping centre as described in the electrical drawings. 9 Place the rod of low level switch (12) on top of the follower plate through the hole on the lid. 10 Using the pressure regulator (19) and the pressure gauge (20), set air pressure to bar. 11 Connect the pressure hose (13) to the pump s pressure connection (P) and the other end of the hose to the grease filter (14). 12 Turn on the pump by turning on the power. 13 Bleed the pressure hose of air by opening the bleed screw (15) of the grease filter. 14 Stop the pump by turning off the power. 15 Using the pressure regulator (19) and the pressure gauge (20), set the pump s air pressure to bar. 9 (39)

12 4.2 Replacing the lubricant drum Lubricant drum replacement in a central lubrication system NOTE Ensure that the system is not under pressure when the drum is being replaced. Before opening the grease filter, remove pressure from the system by opening the bleed screw in the filter plug ( Figure 2, pos. 15). If the system is under pressure when the components are being disconnected or opened, the components or lubricant might be flung in the air causing injury to people or damage to the environment. Note Check that the workspace is clean. When changing the lubricant drum, make sure that no impurities enter the pump, the follower plate or the drum. Impurities may cause damage to the lubrication system or the machine or device it lubricates. Note The numbers in brackets indicate position numbers in Figures 1, 2 and 3 ( pages 2 and 3). 1 Turn off the power from the control or pumping centre. 2 Turn off the air supply by lifting up the shut-off valve button (18) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20). 3 Detach the M12 cable (12) from the pump. 4 Lift the pump out of the lubricant drum and place it on the pump bracket or on a clean plastic base. Be careful not to damage the suction port at the bottom of the pump. 5 Lift the rod of the low level switch (7) from the barrel. 6 Remove the lid (8) from the top of the drum. 7 Use the handles to lift the follower plate out of the barrel. 8 Replace the old lubricant drum with a new one. 9 Place the follower plate in the drum, closely on top of the lubricant. Ensure that air is pushed out from below the follower plate and that the follower plate s suction port starts to fill with lubricant. 10 Fasten the lid onto the lubricant drum with wing screws. 11 Place the pump through the drum lid and follower plate to the barrel. Lock the pump with the set screw in the drum nut so that the lower part of the pump is approximately 2 cm above the bottom of the drum. 12 Place the rod of low level switch (13) on top of the follower plate through the hole on the lid. 13 Remove pressure from the grease filter (14) by opening the bleed screw (15) in the filter plug. 14 Clean the grease filter and the filter cartridge, replace as necessary. 15 Turn on the air supply by pressing down the shut-off valve button (18) or set air pressure to bar using the pressure regulator (19) and the pressure gauge (20). 16 Connect the M12 cable to the pump. 17 Turn on the power from the control or pumping centre. If a low level warning appears, reset it. 10 (39)

13 18 Make a test run. 11 (39)

14 4.2.2 Lubricant drum replacement as a feed or filler pump NOTE Make sure that the pump does not start when the drum is being replaced. Remove pressure from the system. If the system is under pressure when the components are being disconnected or opened, the components or lubricant might be flung in the air causing injury to people or damage to the environment. Note Check that the workspace is clean. When changing the lubricant drum, make sure that no impurities enter the pump, the follower plate or the drum. Impurities may cause damage to the lubrication system or the machine or device it lubricates. Note The numbers in brackets indicate position numbers in Figures 1, 2 and 3 ( pages 2 and 3). 1 Turn off the air supply by lifting up the shut-off valve button (18) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20). 2 Detach the M12 cable (12) from the pump. 3 Lift the pump out of the lubricant drum and place it on the pump bracket or on a clean plastic base. Be careful not to damage the suction port at the bottom of the pump. 4 Lift the rod of the low level switch (7) from the barrel. 5 Remove the lid (8) from the top of the drum. 6 Use the handles to lift the follower plate out of the barrel. 7 Replace the old lubricant drum with a new one. 8 Place the follower plate in the drum, closely on top of the lubricant. Ensure that air is pushed out from below the follower plate and that the follower plate s suction port starts to fill with lubricant. 9 Fasten the lid onto the lubricant drum with wing screws. 10 Place the pump through the drum lid and follower plate to the barrel. Lock the pump with the set screw in the drum nut so that the lower part of the pump is approximately 2 cm above the bottom of the drum. 11 Place the rod of low level switch (7) on top of the follower plate through the hole on the lid. 12 Remove pressure from the grease filter (14) by opening the bleed screw (15) in the filter plug. 13 Clean the grease filter and the filter cartridge, replace as necessary. 14 Turn on the air supply by pressing down the shut-off valve button (18) or set air pressure to bar using the pressure regulator (19) and the pressure gauge (20). 15 Connect the M12 cable to the pump. 16 Make a test run. 12 (39)

15 5 Regular inspections Monthly inspections control of the air regulator/oiler assembly and water removal control of the operation of the pump When the barrel is replaced: Clean the grease filter and the filter cartridge, replace as necessary. 6 Fault isolation 6.1 Fault isolation LED signals Fault isolation is an automatic function. During start-up, right after the first completed stroke, the system checks that the piston works correctly: Both inductive sensors confirm movement within 5 s green light is lit. Only one of the sensors sends a confirmation yellow light is lit. Change the inductive sensors. Neither of the inductive sensors sends a confirmation red light starts blinking. First, check the pressure of the compressed air supply. If the fault is not cleared, change the inductive sensors. 13 (39)

16 6.2 Troubleshooting table Operation disturbance The pump does not start. The pump starts but the pressure does not rise. Cause of operation disturbance Compressed air supply is closed. Pressure of the compressed air feed is not sufficient. Supply voltage is switched off. Pressure of the compressed air feed is not sufficient. Solution Turn on the air supply by pressing down the shut-off valve button (18) ( Figure 6, pos. e) or set air pressure to bar using the pressure regulator (19) and the pressure gauge (20). Check that the pressure at the compressed air regulator of the pumping centre is 3,5-4,5 bar. Check the compressed air supply piping for leaks. Check that the pump LED light is lit. Check that the supply voltage is switched on. Check that the M12 cable is connected. Check the condition of the M12 cable. Check that the pressure at the compressed air regulator of the pumping centre is 3,5-4,5 bar. Check the compressed air supply piping for leaks. NOTE Before checking the following disturbances, turn off the power from the control and pumping centre. Turn off the air supply by lifting up the shut-off valve button ( Figure 6, pos. e) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20). Before opening the grease filter, remove pressure from the system by opening the bleed screw in the filter plug ( Figure 7, pos. 15). If the system is under pressure when the components are being disconnected or opened, the components or lubricant might be flung in the air causing injury to people or damage to the environment. Operation disturbance The pump starts but the pressure does not rise. Cause of operation disturbance The grease filter has clogged. There is air in the suction piping. Solution Clean or replace the filter cartridge of the grease filter. Bleed the pump of air by opening the bleed screw of the grease filter( Figure 7, pos. 15) or the pump s pressure connection (P). Ensure that only grease (no 14 (39)

17 There are impurities in the suction head or the suction port of the pump. air) is coming out of the bleed screw or the pressure connection. Contact Oy SKF Ab. Figure 6 Shut-off valve button (e) Figure 7 Grease filter (14), bleed screw (15) 15 (39)

18 7 Technical data Table 1 SKF-EPB-PUMP-STA, technical data Value Unit Description , C F bar psi MPa Operating temperature range Maximum pressure 1:65 bar Pressure ratio V DC Operating voltage 1.5 W Power consumption 850 g/min Max. pump output ( Figure 9, page 18) 5.5 grams/stro ke Pump output per stroke bar Compressed air supply 300 l/min Max. air consumption ( Figure 9, page 18) 10,000 cst Maximum viscosity 0 2 NLGI Lubricant grade Aluminium, plastic and steel kg kg mm (H L W) Lubricant drum capacity, 1/8 pump Lubricant drum capacity, 1/4 pump Lubricant drum capacity, 1/1 pump Weight, 1/8 pump Weight, 1/4 pump Weight, 1/1 pump Dimensions, 1/8 pump Dimensions, 1/4 pump Dimensions, 1/1 pump Body material 50 mm Pump hose diameter IP65 Protection class 80 db Max. noise level Table 2 Low level switch, technical data Value Unit Description 2 wire sensor, NO Type VDC Operating voltage < 4.6 VDC Voltage drop ma Current load < 0.5 ma Leak current 16 (39)

19 Figure 8 Dimensions, pump with drum STA (1/1, 1/4, 1/8) 17 (39)

20 Unit bar g/min l/min Description Lubricant counter pressure Pump output Pump air consumption Example: In indication (1), the compressed air input is 6 bar, and the counter pressure (Indication 2) is 285 bar, which gives a lubricant output of 330 g/min (Indication 3). To determine the air consumption, follow the 6 bar dashed line to Indication 4 and draw a horizontal line to the air consumption scale (Indication 5; 180 l/min). Figure 9 Pump output curve 18 (39)

21 7.1 Designations Table 3 SKF-EPB-PUMP-STA, designations SKF-EPB-PUMP-A-B Abbreviation Description SKF-EPB-PUMP: SKF-EPB-PUMP SKF Electro-pneumatic Barrel Pump A: 1/8 Lubricant drum capacity: 18 kg 1/4 Lubricant drum capacity: 50 kg 1/1 Lubricant drum capacity: 180 kg B: STA The unit is fixed on the lubricant drum. Example: SKF EPB-PUMP-1/1-STA 7.2 Connections The pump is fixed on the lubricant barrel Lubricant barrel size 1/1 = 180 kg SKF Electro-pneumatic Barrel Pump Figure 10 Connections Hydraulic connections (P, T): P = pressure, lubricant outlet, pipe connector Ø 12 mm T = tank, lubricant input, pipe connector Ø 12 mm Air inlet (A) Push-fit connector 8 mm, 1/4 woven nylon hose Electrical connections (P/C) M12 connector (socket) 19 (39)

22 Figure 11 The pump s M12 connector M12 pin M12 cable wire colours Description 1 brown low level switch (+) 2 white pump control 0 VDC 3 blue pump control 24VDC 4 black low level switch (-) control 5 grey (optional) 20 (39)

23 7.3 Electrical and pneumatic connections to SKF pumping centres SKF Maxilube, delivered after 1 April Connect the M12 cable (3,000 mm) delivered with the replacement kit to the pump s P/C socket and Maxilube s D socket. 2 Cut the low level switch cable to about 1,000 mm. 3 Remove the jacket of the low level switch cable to a 30 mm distance from the cut. Repeat for the tips of individual wires (bk, wh) to a 10 mm distance. Using ferrules on the tips is recommended. 4 Detach parts Y1, Y2 and Y3 of the M12 connector. 5 Push the low level switch cable through Y1 and Y2 and press the cable jacket to the connector by screwing Y1 and Y2 together. 6 Attach the wire tips with screws to part Y3 of the M12 connector (see Table 4 and Figure 12). 7 Screw Y3 and Y2 together. Figure 12 M12 connector of the low level switch Table 4 Connections of the M12 connector of the low level switch M12 M12 wire connector colours Description 1 white (wh) low level switch (+) NO 2 do not connect N/A N/A 3 do not connect N/A N/A 4 black (bk) low level (-) NO 21 (39)

24 switch 22 (39)

25 8 Connect the M12 cable (L = 600 mm) to the M12 connector of the pump and the other end to the M12 Y piece (16) (see Figure 13). 9 Connect the M12 cable (12) leading to the hydraulic unit to the M12 Y piece (16). 10 Connect the M12 connector (25) of the low level switch to the M12 Y piece (16). 11 Turn on the air supply by pressing down the shut-off valve button (18). 12 Turn on the power from the control and pumping centre. Figure 13 M12 connector of the low level switch SKF Maxilube/IF-105 pumping centre, delivered prior to 1 April 2012 Warning Only professional electricians are allowed to make electrical connections. To minimise the risk of electric shock, all power must be disconnected before any work involving handling any conductive parts or opening any part of the system or product. Note A separate installation kit is needed for installing the pump in an existing system ( Figure 4, page 4) (SKF code ) 1 Turn off the power from the control and pumping centre. 2 Turn off the air supply by lifting up the shut-off valve button (18). 23 (39)

26 3 Remove the old pump and attach the plug delivered with the installation kit to SKF Maxilube pumping centre s compressed air inlet (Figure 14, connection A2). Figure 14 Compressed air inlet A2 4 Connect the compressed air distributor (f) delivered with the installation kit to the air regulator/oiler assembly s output port (e), see Figure Connect the following components to the compressed air distributor: SKF Maxilube pumping centre s air supply hose to port (h) and the EPB pump s air supply hose to port (i), see Figure 15. Figure 15 Compressed air connections 6 Open the metal cover (a) of the SKF Maxilube pumping centre and unscrew the nut (b) below it, see Figure 16. Then lift off the lid (c) and the shell (d) of the pump. 24 (39)

27 Figure 16 Accessing the inner parts of the pumping centre 7 Detach connectors (j) and (k) from the circuit board, see Figure 17. Pull the low level switch s M12 connector out of socket D at the bottom of SKF Maxilube pumping centre, and pull out the detached wire set. Figure 17 Wire set removal 8 Detach solenoid valve plugs MV1, MV2 and MV3, see Figure 17. Pull out the detached wire set. 9 Connect solenoid valve plugs MV1, MV2 and MV3 of the wire set (Figure 18, delivered with 25 (39)

28 the installation kit) in the order shown in Figure 19. Note The plugs must be placed in the correct sockets. Each plug s cable shell is marked with the corresponding MV marking. Check also that the gaskets under the plugs are in the correct position. Change the gaskets as necessary. Figure 18 Wire set Figure 19 Solenoid valve connections 26 (39)

29 10 Connect the wire set s header plug to socket (I) as shown in Figure First, detach the wire set s connector (n). Then, plug the wiring set s M12 connector (m) in socket D at the bottom of SKF Maxilube pumping centre. 12 When the wire set has been attached, reconnect the connector (n). Figure 20 Connecting the wire set 27 (39)

30 13 Cut the low level switch cable to about 1,000 mm. 14 Remove the jacket of the low level switch cable to a 30 mm distance from the cut. Repeat for the tips of individual wires (bk, wh) to a 10 mm distance. Using ferrules on the tips is recommended. 15 Detach parts Y1, Y2 and Y3 of the M12 connector. 16 Push the low level switch cable through Y1 and Y2 and press the cable jacket to the connector by screwing Y1 and Y2 together. 17 Attach the wire tips with screws to part Y3 of the M12 connector (see Table 5 and Figure 21). 18 Screw Y3 and Y2 together. Figure 21 M12 connector of the low level switch Table 5 Connections of the M12 connector of the low level switch M12 M12 wire connector colours Description 1 white (wh) low level switch (+) NO 2 do not connect N/A N/A 3 do not connect N/A N/A 4 black (bk) low level switch (-) NO 28 (39)

31 19 Connect the M12 cable (L = 600 mm) to the M12 connector of the pump and the other end to the M12 Y piece (16) (see Figure 22). 20 Connect the M12 cable (12) leading to the hydraulic unit to the M12 Y piece (16). 21 Connect the M12 connector (25) of the low level switch to the M12 Y piece (16). 22 Turn on the air supply by pressing down the shut-off valve button (18). 23 Turn on the power from the control and pumping centre. Figure 22 M12 connector of the low level switch 24 Connect the M12 cable (3,000 mm) delivered with the installation kit to the pump s P/C socket and Maxilube s D socket. 25 Mount the hydraulic unit s shell (d), lid (c), nut (b) and metal cover (a) in their original positions (see Figure 15). 26 Turn on the air supply by pressing down the shut-off valve button (18). 27 Turn on the power from the control and pumping centre. 29 (39)

32 7.3.3 SKF Maxilube hydraulic unit 24V, delivered prior to 1 April 2012 Warning Do not make the connection if the operating voltage of the hydraulic unit is 115 VAC or 230 VAC. The operating voltage of the hydraulic part must always be checked on the hydraulic part type plate before starting to make the connection. Warning Only professional electricians are allowed to make electrical connections. To minimise the risk of electric shock, all power must be disconnected before any work involving handling any conductive parts or opening any part of the system or product. Note A separate installation kit is needed for installing the pump in an existing system ( Figure 4, page 4) (SKF code ) 1 Turn off the power from the control and pumping centre. 2 Turn off the air supply by lifting up the shut-off valve button (18). 3 Remove the old pump and attach the plug delivered with the installation kit to SKF Maxilube pumping centre s compressed air inlet (Figure 23, connection A2). Figure 23 Compressed air inlet A2 30 (39)

33 4 Connect the compressed air distributor (f) delivered with the installation kit to the air regulator/oiler assembly s output port (e), see Figure Connect the following components to the compressed air distributor: SKF Maxilube pumping centre s air supply hose to port (h) and the EPB pump s air supply hose to port (i), see Figure 24. Figure 24 Compressed air connections 6 Open the metal cover (a) of the SKF Maxilube pumping centre and unscrew the nut (b) below it, see Figure 25. Then lift off the lid (c) and the shell (d) of the pump. Figure 25 Accessing the hydraulic unit 7 Detach the wires of the low level switch, i.e. o: white and p: black, see Figure 26. Remove the cable of the low level switch from the hydraulic unit. Wires q (brown) and r (blue) will remain connected in parallel with new wires. 31 (39)

34 Figure 26 The connector strip of SKF Maxilube s hydraulic unit before new connections 8 Connect the M12 cable (3,000 mm) delivered with the installation kit to the pump s P/C socket 9 Cut off the plug on the other end of the M12 cable. Pass the cable through the low level switch s cable entry at the bottom of the hydraulic unit. 10 Remove the jacket to a 60 mm distance from the cut. Repeat for the tips of individual wires to a 10 mm distance. Using ferrules on the tips is recommended. 11 Connect the free wires of the M12 cable to the hydraulic unit s connector strip in the order indicated in Table 6. Table 6 Strip connector diagram for SKF Maxilube s hydraulic unit Maxilube strip connector M12 wire colours Description 1 brown low level switch (+) 5 white pump control 0 VDC 4 blue pump control 24VDC 2 black do not connect grey low level switch (-) control (optional) Figure 27 The connector strip of SKF Maxilube s hydraulic unit with completed connections 32 (39)

35 12 Cut the low level switch cable to about 1,000 mm. 13 Remove the jacket of the low level switch cable to a 30 mm distance from the cut. Repeat for the tips of individual wires (bk, wh) to a 10 mm distance. Using ferrules on the tips is recommended. 14 Detach parts Y1, Y2 and Y3 of the M12 connector. 15 Push the low level switch cable through Y1 and Y2 and press the cable jacket to the connector by screwing Y1 and Y2 together. 16 Attach the wire tips with screws to part Y3 of the M12 connector (see Table 7 and Figure 28). 17 Screw Y3 and Y2 together. Figure 28 M12 connector of the low level switch Table 7 Connections of the M12 connector of the low level switch M12 M12 wire connector colours Description 1 white (wh) low level switch (+) NO 2 do not connect N/A N/A 3 do not connect N/A N/A 4 black (bk) low level switch (-) NO 33 (39)

36 18 Connect the M12 cable (L = 600 mm) to the M12 connector of the pump and the other end to the M12 Y piece (16) (see Figure 29). 19 Connect the M12 cable (12) leading to the hydraulic unit to the M12 Y piece (16). 20 Connect the M12 connector (25) of the low level switch to the M12 Y piece (16). 21 Turn on the air supply by pressing down the shut-off valve button (18). 22 Turn on the power from the control and pumping centre. Figure 29 M12 connector of the low level switch 23 Mount the hydraulic unit s shell (d), lid (c), nut (b) and metal cover (a) in their original positions (see Figure 24). 24 Turn on the air supply by pressing down the shut-off valve button (18). 25 Turn on the power from the control and pumping centre. 34 (39)

37 7.3.4 SG-2102 hydraulic unit Warning Only professional electricians are allowed to make electrical connections. To minimise the risk of electric shock, all power must be disconnected before any work involving handling any conductive parts or opening any part of the system or product. Note A separate installation kit is needed for installing the pump in an existing system ( Figure 4, page 4) (SKF code ) 1 Turn off the power from the control and pumping centre. 2 Turn off the air supply by lifting up the shut-off valve button (18) or set air pressure to 0 bar using the pressure regulator (19) and the pressure gauge (20). 3 Connect the compressed air distributor delivered with the installation kit to the output port of the air regulator/oiler assembly. If necessary, use fitting (Figure 30, pos. s). 4 Connect the compressed air hose to port (u) as shown in Figure 30. Connect the other end of the compressed air hose to the air input port of SG-2102 hydraulic unit. 5 Connect EPB pump s compressed air supply hose to port (v), see Figure Plug unused ports (t) with stoppers delivered with the installation kit. Figure 30 Compressed air connections 7 Cut off the plug on the other end of the M12 cable. Pass the cable into SG-2102 hydraulic unit. 8 Remove the jacket to a 60 mm distance from the cut. Repeat for the tips of individual wires to a 10 mm distance. Using ferrules on the tips is recommended. 9 Connect the free wires of the M12 cable to the SG-2102 hydraulic unit s connector strip. The correct order is indicated in Table (39)

38 Table 8 Hydraulic unit SG-2102 strip connector connection diagram SG-2102 M12 wire strip colours connector Description 10 brown (br) low level switch (+) 2 white (wh) pump control 0 VDC 3 blue (bl) pump control 24VDC 11 black (bk) do not connect grey low level switch (-) control (optional) 36 (39)

39 10 Cut the low level switch cable to about 1,000 mm. 11 Remove the jacket of the low level switch cable to a 30 mm distance from the cut. Repeat for the tips of individual wires (bk, wh) to a 10 mm distance. Using ferrules on the tips is recommended. 12 Detach parts Y1, Y2 and Y3 of the M12 connector. 13 Push the low level switch cable through Y1 and Y2 and press the cable jacket to the connector by screwing Y1 and Y2 together. 14 Attach the wire tips with screws to part Y3 of the M12 connector (see Table 9 and Figure 31). 15 Screw Y3 and Y2 together. Figure 31 M12 connector of the low level switch Table 9 M12 connector (connections) M12 M12 wire connector colours Description 1 white (wh) low level switch (+) NO 2 do not connect N/A N/A 3 do not connect N/A N/A 4 black (bk) low level switch (-) NO 16 Connect the M12 cable (L = 600 mm) to the M12 connector of the pump and the other end to the M12 Y piece (16) (see Figure 32). 17 Connect the M12 cable (12) leading to the hydraulic unit to the M12 Y piece (16). 18 Connect the M12 connector (25) of the low level switch to the M12 Y piece (16). 19 Turn on the air supply by pressing down the shut-off valve button (18). 20 Turn on the power from the control and pumping centre. 37 (39)

40 Figure 32 M12 connector of the low level switch 38 (39)

41 8 Spare parts Table 10 Spare parts for SKF-EPB-PUMP-STA. See Figure 33. Position Description Order code 1 Inductive sensor M8x1 L Signal light, 3 colour LED Circuit board Pneumatic valve Inductive sensor M8x1 L M12 connector Figure 33 Spare parts for SKF-EPB-PUMP-STA 39 (39)

42 Table 11 Spare parts for MAX-LIDSET-XXX-STA-EPBP lid sets. See Figure 34. Position Description Order code 7 Low level switch M12 STA Drum lid 1/1 (180 kg) Drum lid 1/4 (50 kg) 9 Follower plate 1/1 (180 kg) Follower plate 1/4 (50 kg) Hose assembly Compressed air hose M12 cable (L = mm) Hose assembly Grease filter (complete) Grease filter cartridge Grease filter bleed screw M12 Y piece M12 cable (L = 600 mm) Figure 34 Spare parts for the MAX-LIDSET-XXX-STA-EPBP lid set 40 (39)

43 Table 12 Spare parts for air regulator/oiler assemblies See Figure 35. Position Description Order code 18 Shut-off valve Pressure regulator Pressure gauge Figure 35 Air regulator/oiler assembly MAXILUBE-SET-STA-EPBP 41 (39)

44 Figure 36 Order codes Item Pumps Order code Prodmast code SKF-EPB-PUMP-1/1-STA VGBN SKF-EPB-PUMP-1/4-STA VGBN Installation kit (contains components for attaching existing pneumatic and electric connections to the EPB pump) INSTALLATION KIT STA-EPBP VGBV Lid sets MAX-LIDSET-1/1-STA-EPBP VGBV MAX-LIDSET-1/4-STA-EPBP VGBV Compressed air regulator/oiler assembly MAXILUBE-SET-STA-EPBP VGBV Power supply EPBP-UNIPOWER 24V 0.63A VAC VGBV Contact information Oy SKF Ab P.O. Box 80 (Teollisuustie 6) FI MUURAME FINLAND Tel (0) Fax +358 (0) (39)