Lincoln SKF IG502-2-E User manual

Operating Instructions
IG502-2-E - Universal control unit
(for commercial vehicles) for NLGI
Also as a replacement for the following predecessor models: IG471-21, IG472-11, IG434-1, IG472-22, IG433-5-51, ...
Created on:
19.01.2023
Document no.:
951-180-193-EN
Version:
01
Read these instructions before
installation or start
-up of the
product and keep them readily
available for later consultation!

2
EU Declaration of Conformity in accordance with Directive 2014/30/EU, Annex IV
The manufacturer hereby declares under its sole responsibility conformity of the product described below with all relevant harmonization legislation of the
European Union at the time of placing on the market.
Designation:
Universal control unit for use in centralized lubrication systems for commercial vehicles
Type / item number:
IG502-2-E+912, IG502-2-E+924
Year of manufacture:
See type plate
Furthermore, the following directives and standards were applied in the respective applicable areas:
2011/65/EU: RoHS II
2014/30/EU: Electromagnetic Compatibility
EN IEC 63000:2018
Berlin, 10.11.2022
Jürgen Kreutzkämper
Richard Lindemann
Manager, R&D
Germany
Manager, SE
Berlin
Manufacturer: SKF Lubrication Systems Germany GmbH, Motzener Strasse 35/37, 12277 Berlin, Germany
UK Declaration of Conformity pursuant to the Electromagnetic Compatibility
Regulations 2016 No. 1091, Annex IV
The manufacturer hereby declares under its sole responsibility conformity of the product described below with all relevant harmonization legislation of the
United Kingdom at the time of placing on the market.
Designation:
Universal control unit for use in centralized lubrication systems for commercial vehicles
Type / item number:
IG502-2-E+912, IG502-2-E+924
Year of manufacture:
See type plate
Furthermore, the following regulations and standards were applied in the respective applicable areas:
•Electromagnetic Compatibility Ordinance 2016 No. 1091
•The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012 No. 3032
EN IEC 63000:2018
Berlin, 10.11.2022
Jürgen Kreutzkämper
Richard Lindemann
Manager, R&D
Germany
Manager, SE
Berlin
Manufacturer: SKF Lubrication Systems Germany GmbH, Motzener Strasse 35/37, 12277 Berlin, Germany

3
Masthead
Manufacturer
SKF Lubrication Systems Germany GmbH
Email: Lubrication-[email protected]
www.skf.com/lubrication
Berlin Plant
Motzener Strasse 35/37
12277 Berlin
Germany
Tel. [phone]
Fax [phone]
Walldorf Plant
Heinrich-Hertz-Strasse 2-8
69190 Walldorf, Germany
Germany
Tel.: [phone]
Fax: [phone]
Authorized local distributors
- Great Britain -
SKF (U.K.) Limited,
2 Canada Close, Banbury, Oxfordshire,
OX16 2RT, GBR.
- North America -
SKF Lubrication Business Unit
Lincoln Industrial
5148 North Hanley Road, St. Louis,
MO. 63134 USA
- South America -
SKF Argentina Pte. Roca 4145,
CP 2001 Rosario, Santa Fe
Warranty
The instructions contain no statements regarding the warranty
or liability for defects. That information can be found in our
General Terms of Payment and Delivery.
Training
We conduct detailed training in order to enable maximum
safety and efficiency. We recommend taking advantage of this
training. For further information, contact your authorized SKF
dealer or the manufacturer.

4
Table of contents
Masthead............................................................................................... 3
Table of contents ................................................................................. 4
Safety alerts, visual presentation, and layout ................................ 5
1. Safety instructions.......................................................................... 6
1.1 General safety instructions ..................................................... 6
1.2 General electrical safety instructions.................................... 6
1.3 General behaviour when handling the product................... 6
1.4 Intended use .............................................................................. 6
1.5 Persons authorized to use the product ................................ 6
1.6 Referenced documents............................................................ 7
1.7 Prohibition of certain activities............................................... 7
1.8 Painting plastic components and seals................................. 7
1.9 Safety markings on the product ............................................ 7
1.10 Note on the type plate........................................................... 7
1.11 Notes on CE marking............................................................. 7
1.12 Note on UKCA marking ......................................................... 7
1.13 Note on ECE mark..................................................................7
1.14 Note on China RoHS mark ................................................... 7
1.15 Emergency shutdown............................................................ 7
1.16 Assembly, maintenance, fault, repair................................. 7
1.17 First start-up, daily start-up................................................ 8
2. Overview, functional description .................................................. 9
2.1 Functional description.............................................................. 9
2.2 Use as replacement unit.......................................................... 9
2.2.1 Factory settings on IG502-2-E.................................. 9
3. Technical data................................................................................10
4. Delivery, returns, storage............................................................11
4.1 Delivery.....................................................................................11
4.2 Return shipment.....................................................................11
4.3 Storage .....................................................................................11
4.4 Storage temperature range..................................................11
4.5 Declaration of decontamination...........................................11
5. Assembly.........................................................................................12
5.1 Overview of the electrical connections................................12
5.2 Replacement unit....................................................................12
5.2.1 Replacing a predecessor model ...............................12
5.2.2 Replacing other control units ...................................13
5.3 Predecessor model being replaced – programming data
for the IG502-2-E .........................................................................13
5.4 Activation of a pneumatic pump..........................................14
5.4.1 Operation without electronic system monitoring.14
5.4.2 Operation with electronic system monitoring.......14
6. Operation........................................................................................15
6.1 Display and operating unit....................................................15
6.2 Three-digit LED display.........................................................15
6.3 Function indication by LEDs .................................................17
6.4 Pushbutton operation............................................................17
6.5 External control light: SL.......................................................17
6.6 Display mode ...........................................................................18
6.7 Programming ..........................................................................19
6.7.1 Start programming mode.........................................19
6.7.2 Changing the pause time or pump run time.........20
6.7.3 Changing the system monitoring ............................20
6.7.4 Change operating modes ..........................................21
6.7.5 Change code ................................................................22
6.7.6 Programming ranges.................................................22
6.7.7 Display ranges.............................................................23
6.8 Operating modes.....................................................................23
6.8.1 Timer operation (pause and pump operation are
time-dependent) ...................................................................23
6.8.2 Counter operation (pause depends on the number
of pulses).................................................................................23
6.8.3 Special forms of control ............................................23
6.8.4 Operation without system monitoring....................23
6.8.5 Operation with system monitoring..........................23
6.8.6 Monitoring via pressure switch................................24
6.8.7 Monitoring via cycle switch.......................................25
6.9 Replacement unit....................................................................26
6.9.1 Replacement of IG471-21........................................26
6.9.2 Replacement of IG472-11........................................27
6.9.3 Replacement of IG434-1 ..........................................28
6.9.4 Replacement of IG472-22........................................29
6.9.5 Replacement of IG433-5-51 ...................................30
7. Maintenance and repair...............................................................31
8. Cleaning ..........................................................................................32
8.1 Basics ........................................................................................32
8.2 Interior cleaning ......................................................................32
8.3 Exterior cleaning .....................................................................32
9. Faults, causes, and remedies......................................................33
9.1 Displaying errors.....................................................................33
9.2 Delete fault notification..........................................................33
9.3 Displaying errors.....................................................................33
9.4 Delayed signal from cycle switch .........................................33
9.5 No signal from cycle switch ..................................................34
9.6 No signal from pressure switch ...........................................34
9.7 Recording fault times.............................................................34
9.7.1 Fault-state counter....................................................34
9.7.2 Fault-hours counter...................................................35
10. Repairs..........................................................................................36
11. Shutdown, disposal ....................................................................36
11.1 Temporary shutdown..........................................................36
11.2 Permanent shutdown, disassembly..................................36
11.3 Disposal..................................................................................36
12. Spare parts ..................................................................................36
13. Appendix.......................................................................................37
13.1 China RoHS Table ................................................................37

5
Safety alerts, visual
presentation, and layout
While reading these instructions, you will encounter various
symbols, illustrations, and text layouts intended to help you
navigate and understand the instructions. Their meaning is
explained below.
Safety alerts:
Activities that present specific hazards (to life and limb or
possible damage to property) are indicated by safety alerts.
Always be sure to follow the instructions given in the safety
alerts.
<
DANGER
These safety alerts indicate an imminent danger.
Ignoring them will result in death or serious injury
<
WARNING
These safety alerts indicate potentially imminent
danger. Ignoring them
could result in death or
serious injury
<
CAUTION
These safety alerts indicate potentially imminent
danger. Ignoring them could result in minor injury
<
NOTICE
These safety alerts indicate a potentially harmful
situation. Ignoring them could result in damage to
property or malfunctions
Illustrations:
The illustrations used depict a specific product. For other
products, they may have the function of a diagram only. This
does not alter the basic workings and operation of the product.
Text layout:
•First-order bulleted lists: Items on a bulleted list start with
a solid black dot and an indent.
–Second-order bulleted lists: If there is a further listing of
subitems, the second-order bulleted list is used.
1 Legend: A legend explains the numbered contents of an
illustration, presented as a numbered list. Items in a legend
start with a number (with no dot) and an indent.
–Second-order legend: In some cases, the numbered
contents of an image represent more than just one object.
A second-order legend is then used.
1.Instruction steps: These indicate a chronological sequence
of instruction steps. The numbers of the steps are in bold and
are followed by a period. If a new activity follows, the
numbering starts again at “1.”
–Second-order instruction steps: In some cases, it is
necessary to divide up a step into a few substeps. A
sequence of second-order instruction steps is then used.

6
1. Safety instructions
1.1 General safety instructions
•Putting the products into operation or operating them without
having read the instructions is prohibited. The operator must
ensure that the instructions are read and understood by all
persons tasked with working on the product or who supervise
or instruct such persons. Retain the instructions for further
use.
•The product may only be used in awareness of the potential
dangers, in proper technical condition, and according to the
information in this manual.
•Any faults that could affect safety must be remedied
according to responsibility. The supervisor must be notified
immediately in case of malfunctions outside one's individual
scope of responsibility.
•Unauthorized modifications and changes can have an
unpredictable effect on safety and operation. Unauthorized
modifications and changes are therefore prohibited. Only
original SKF spare parts and SKF accessories may be used.
•Any unclear points regarding proper condition or correct
assembly/operation must be clarified. Operation is prohibited
until issues have been clarified.
•The components used must be suitable for the intended use
and the applicable operating conditions, e.g. max. operating
pressure and ambient temperature range, and must not be
subjected to torsion, shear, or bending.
1.2 General electrical safety instructions
•Electrical devices must be kept in proper condition. This must
be ensured by periodic inspections in accordance with the
relevant applicable standards and technical rules. The type,
frequency, and scope of the inspections must be determined
in accordance with the risk assessment to be carried out by
the operator. Work on electrical components may be
performed only by qualified electricians. Connect the electrical
power only in accordance with the valid terminal diagram and
in observance of the relevant regulations and the local
electrical supply conditions.
•Work on electrical components may be performed only in a
voltage-free state and using tools suitable for electrical work.
Do not touch cables or electrical components with wet or
moist hands.
•Fuses must not be bridged. Always replace defective fuses
with fuses of the same type.
•Ensure proper connection of the protective conductor for
products with protection class I. Observe the specified
enclosure rating.
•The operator must implement appropriate measures to
protect vulnerable electrical devices from the effects of
lightning during use. The electrical device is not furnished
with a grounding system for the dissipation of the respective
electric charge and does not have the voltage strength
necessary to withstand the effects of lightning.
1.3 General behaviour when handling the
product
•Familiarize yourself with the functions and operation of the
product. The specified assembly and operating steps and their
sequences must be observed.
•Keep unauthorized persons away.
•Wear personal protective equipment always.
•Precautionary operational measures and instructions for the
respective work must be observed.
•In addition to these Instructions, general statutory regulations
for accident prevention and environmental protection must be
observed.
•Precautionary operational measures and instructions for the
respective work must be observed. Uncertainty seriously
endangers safety.
•Safety-related protective and safety equipment must not be
removed, modified or affected otherwise in its function and is
to be checked at regular intervals for completeness and
function.
•If protective and safety equipment has to be dismantled, it
must be reassembled immediately after finishing the work,
and then checked for correct function.
•Remedy occurring faults in the frame of responsibilities.
Immediately inform your superior in the case of faults beyond
your competence.
•Never use parts of the centralized lubrication system or of the
machine as standing or climbing aids.
1.4 Intended use
The product is intended solely for installation in another
machine.
Use is only permitted within the scope of commercial or
economic activity by professional users, in compliance with the
specifications, technical data, and limits specified in this manual.
1.5 Persons authorized to use the
product
Operator
A person who is qualified by training, knowledge and experience
to carry out the functions and activities related to normal
operation. This includes avoiding possible hazards that may
arise during operation.
Specialist in electrics
Person with appropriate professional education, knowledge and
experience to detect and avoid the hazards that may arise from
electricity.
Specialist in mechanics
Person with appropriate professional education, knowledge and
experience to detect and avoid the hazards that may arise
during transport, installation, start-up, operation, maintenance,
repair and disassembly.

7
1.6 Referenced documents
In addition to this manual, the following documents must be
observed by the respective target group:
•Company instructions and approval rules
If applicable:
•Safety data sheet of the lubricant used
•Project planning documents
•Supplementary information regarding special designs of the
pump. This you will find in the special system documentation.
•Instructions for other components for setting up the
centralized lubrication system.
1.7 Prohibition of certain activities
•Alterations to the control circuit board beyond adjustment of
lubrication times and interval times or replacement in case of
defect
•Alterations to the power supply board beyond replacement in
case of defect
1.8 Painting plastic components and
seals
The painting of any plastic components and seals of the
products described is prohibited. Completely mask or remove
plastic components before painting the main machine.
1.9 Safety markings on the product
No safety markings on the product
NOTE
In accordance with the results of the workstation risk
assessment, additional labels (e.g., warnings, safety signs,
prohibition signs, or labels in accordance with CLP/GHS) are
to be attached by the operator if necessary.
1.10 Note on the type plate
The type plate provides important data such as the type
designation order number, and sometimes regulatory
characteristics. To avoid loss of this data in case the type plate
becomes illegible, these characteristics should be entered in the
manual.
Fig. 1
Type plate (example)
1.11 Notes on CE marking
CE marking is effected following the requirements
of the applied directives requiring a CE marking:
•2014/30/EC Electromagnetic Compatibility
•2011/65/EU Directive on the restriction of the use of certain
hazardous substances in electrical and electronic equipment
(RoHS II)
1.12 Note on UKCA marking
The UKCA conformity marking confirms the
product’s conformity with the applicable legal
provisions of Great Britain.
1.13 Note on ECE mark
The ECE test mark (E1) confirms that an ECE
type approval (components requiring approval on
motor vehicles) has been granted for a product
which bears this mark on its type plate.
1.14 Note on China RoHS mark
The China RoHS mark confirms that there is no
danger to persons or the environment from the
regulated substances contained within for the
intended period of use (year number shown in the
circle).
1.15 Emergency shutdown
This is done by a course of action to be defined by the operator.
1.16 Assembly, maintenance, fault,
repair
Prior to the start of this work, all relevant persons must be
notified of it. At a minimum, the following safety measures must
be taken before any work is done:
•Unauthorized persons must be kept away
•Mark and secure the work area
•Cover adjacent live parts
•Dry any wet, slippery surfaces or cover them appropriately
•Cover hot or cold surfaces appropriately
Where applicable:
•Depressurize
•Isolate, lock and tag out
•Check to ensure live voltage is no longer present
•Ground and short-circuit
The product should be protected as much as possible from
humidity, dust, and vibration, and should be installed so that it
is easily accessible. Ensure an adequate distance from sources
of heat or cold. Any visual monitoring devices present, such as
pressure gauges, min./max. markings, or oil level gauges must
be clearly visible. Observe the mounting position requirements.

8
Drill required holes only on non-critical, non-load-bearing
parts of the operator's infrastructure. Use existing holes where
possible. Avoid chafe points. Immobilize any moving or detached
parts during the work. Adhere to the specified torques.
If guards or safety devices need to be removed, they must be
reinstalled immediately following conclusion of work and then
checked for proper function.
Check new parts for compliance with the intended use before
using them.
Avoid mixing up or incorrectly assembling disassembled parts.
Label parts. Clean any dirty parts.
1.17 First start-up, daily start-up
Ensure that:
•All safety devices are fully present and functional
•All connections are properly connected
•All parts are correctly installed
•All warning labels on the product are fully present, visible, and
undamaged
•Illegible or missing warning labels are immediately replaced

9
2. Overview, functional
description
2.1 Functional description
The IG502-2-E universal control unit is used to control and
monitor centralized lubrication systems on commercial vehicles.
The control unit's functions can be programmed.
NOTE
Replacement of previous SKF control units: see section 5.3
Predecessor model being replaced
– programming data for
the IG502-2-E
The control elements have a film that protects them from
humidity and contamination. The unit possesses non-volatile
data memory which The configuration data and parameters are
stored here. This allows the control unit to function without a
continuous power supply.
If an external SL control light is installed in the vehicle cab, it
lights up for 3 seconds when the ignition is switched on
NOTE
The IG502-2-E is available in two versions:
12 V DC (IG502-2-E+912) and 24 V DC (IG502-2-E+924)
Fig. 2
Unit view and mounting dimensions – front
Fig. 3
Unit view and mounting dimensions – side
Legend to Figures 2 and 3:
1 Mounting lugs
2 Display and operating unit
3 Plug for cable connection
2.2 Use as replacement unit
The IG502-2-E universal control unit is used to control and
monitor centralized lubrication systems on commercial vehicles.
The functions of the IG502-2-E are programmable, and it
thus replaces a series of older control units.
2.2.1 Factory settings on IG502-2-E
When the IG502-2-E is delivered from the factory, the following
settings are programmed on it:
Pump run time (tCO): 2.6 min
Pause time (tPA): 9 h
Code: 000 (programming protection)
System monitoring: Pressure switch is activated
(COP = PS)
These settings match the operating mode of the predecessor
model IG433-5-51 and must be reprogrammed if necessary

10
3. Technical data
Table 1
Technical data
Designation
Value
<Conte nt>
Nominal voltage UN
DC: 12 V or 24 V
Enclosure rating
IP 20, DIN 40050 /
plug IP 00
Max. load, output M
5 A at 24 V, 5 A at 12 V
SL output
4 W
Data retention
Unlimited
Working temperature
-25 °C to +75 °C
Storage temperature
-25 °C to +75 °C
Fuse protection, max.
5 A
Dimensions L x W x H
138 x 65 x 40
Programmable
pause times
0.1 h to 99.9 h
Programmable pump run
time
0.1 min to 99.9 min
Programmable pulses
1 to 999
Elapsed-hours memory
0 to 99999.9 h
Fault-hours memory
0 to 99999.9 h

11
4. Delivery, returns, storage
4.1 Delivery
After receipt of the shipment, it must be inspected for any
shipping damage and for completeness according to the
shipping documents. Immediately inform the transport carrier
of any shipping damage. The packaging material must be
preserved until any discrepancies are resolved.
4.2 Return shipment
Before return shipment, all contaminated parts must be
cleaned. If this is not possible or practical, e.g. if it would impede
fault detection in the case of complaints, the medium used must
always be specified. In the case of products contaminated with
hazardous substances as defined by GHS or CLP regulations,
the safety data sheet (SDS) must be sent with the product and
the packaging must be labelled in accordance with GHS/CLP.
There are no restrictions for land, air, or sea transport. The
choice of packaging should be based on the specific product and
the stresses to be expected during transport (e.g., necessary
anti-corrosion measures in the case of shipment by sea). In the
case of wooden packaging, the applicable import regulations
and the IPPC standards must be observed. Required certificates
must be included in the shipping documents. The following
information, as a minimum, must be marked on the packaging
of return shipments.
Fig. 4
Marking of return shipments
4.3 Storage
The following conditions apply to storage:
•Dry, low-dust, vibration-free, in closed rooms
•No corrosive, aggressive substances at the storage location
(e.g., UV rays, ozone)
•Protected against animals (insects, rodents)
•If possible, keep in the original product packaging
•Protected from nearby sources of heat or cold
•In the case of large temperature fluctuations or high humidity,
take appropriate measures (e.g., heating) to prevent the
condensation of water
•Before usage, check products for damage that may have
occurred during storage. This applies in particular to parts
made of plastic (due to embrittlement).
4.4 Storage temperature range
For parts not filled with lubricant, the permitted storage
temperature is the same as the permitted ambient temperature
range (see “Technical data”).
4.5 Declaration of decontamination
If the product came in contact with harmful substances, make
sure to thoroughly clean the product before returning it to us.
Due to statutory provisions and for the safety of our employees
and operation facilities we further need a fully completed and
signed “Declaration of decontamination”.

12
5. Assembly
The unit must be installed inside a closed area in the vehicle,
where it is protected from environmental influences
Fig. 5
Mounting lugs
The unit is mounted using lugs (Fig. 5).
The IG502-2-E is contained in a housing that meets
protection class IP 20. The plug has the protection class IP 00.
Fig. 6
Electrical connection of external illuminated pushbuttons
Legend to Figure 6:
+SL External control light
31 Ground
DK/MK External pushbutton (timer operation) / counter input
(counter operation)
15 Positive pole of vehicle electrical system
Order No.: 664-85421-9
If the control unit is mounted in an inaccessible location, we
recommend also installing an illuminated pushbutton on the
dashboard for fault indication and function checking (Fig. 6).
The accessories required for the lubrication system, such as a
cable set and a cycle or pressure switch, can be obtained from
SKF Lubrication Systems Germany GmbH.
5.1 Overview of the electrical connections
Fig. 7
Electrical connection assignment diagram
Fig. 8
Tab receptacle housing for cable set
Legend to Figures 7 and 8:
PS/CS Pressure switch or cycle switch
15 Positive pole of vehicle electrical system
+M Pump motor
+SL External control light
DK/MK External pushbutton (timer operation) / counter input
(counter operation)
31 Ground
Z Ignition lock
5.2 Replacement unit
5.2.1 Replacing a predecessor model
NOTE
Compare the voltage of the vehicle electrical system with
the voltage specification of the IG502
-2-E control unit.
There are versions for 12 V DC and 24 V DC.

13
1.Read the item number (IG....) printed on the old unit that you
are replacing, in order to determine the operating mode that
you need to program on the new IG502-2-E unit.
2.Write down the values that were set on the old unit for pause
time and, if applicable, operating time.
3.Uninstall the previous control unit and replace it with the
IG502-2-E. The mounting dimensions and the electrical plug
connection are identical.
4.Set the operating mode and the settings as instructed in the
quick reference guides: see section 5.2 Replacement unitor
section 6.7 Programming.
NOTE
Use the control panel of the IG502-2-E for the
programming. The IG502
-2-E must be electrically
connected to the vehicle.
5.2.2 Replacing other control units
Section 5.3 Predecessor model being replaced – programming
data for the IG502-2-Econtains a list of other predecessor
models that can be replaced by the IG502-2-E if needed. Refer
to that table for the values that need to be programmed in each
case.
NOTE
Observe sections 6.7 Programmingand 6.8 Operating
modes
5.3 Predecessor model being replaced – programming data for the IG502-2-E
Table 2
Predecessor model being replaced – programming data for the IG502-2-E
Type of centralized lubrication system
To be programmed on IG502-2-E
Fluid grease with KFU
…
Grease with KFG …
Pause time
Pump cycle time
Monitoring
Control units
being replaced
With
pressure
switch
Without
pressure
switch
With cycle
switch
Without
cycle switch
Pause
Value
Contact
Value
PS
CS
OFF
Page
IG433-5-51
•
tPA
*) h
tCO
2.6 min
•
31
IG433-5-51/S2
•
tPA
*) h
tCO
2.6 min
•
13
IG433-5-51/S6
•
tPA
*) h
tCO
18 min
•
13
IG433-5-51/S7
•
tPA
*) h
tCO
2.6 min
•
13.15
IG472-11
•**
tPA
*) h
tCO
***
•
25
IG472-22
•
tPA
*) h
tCO
***
•
29
IG472-22/S1
•
tPA
*) h
tCO
***
•
13.15
IG472-33
•
cPA
*) Imp.
tCO
***
•
13.15
IG472-33/S1
•
cPA
*) Imp.
tCO
***
•
13.15
IG471-21
•**
tPA
*) h
tCO
*) min
•
23
IG471-21/S1
•**
tPA
*) h
tCO
*) min
•
13
IG471-21/S2
•**
tPA
*) h
tCO
*) min
•
13
IG434-1
•
tPA
*) h
tCO
*) min
•
27
IG434-3
•
cPA
*) Imp.
tCO
*) min
•
13
IG434-5
•
tPA
*) h
tCO
3 min
•
13.15
IG434-6
•
cPA
*) Imp.
tCO
3 min
•
13.15
IG434-8
•
tPA
*) h
tCO
*) min
•
13.15
When replacing a control unit with negative cycle switch input such as IG434-2, IG434-4, or IG472-11, the minus connection of the cycle
switch must be placed on plus.
* Copy the system-specific settings of the unit being replaced.
** Connection 30 is not used! It must be removed from the connector plug.
*** The time for a lubrication cycle must be determined and must be set as the pump run time value.

14
5.4 Activation of a pneumatic pump
NOTE
Only on centralized lubrication systems for NLGI Grade 00
and 000 greases!
The pneumatic pump is activated by a 3/2 directional control
valve. During the pause time, this valve discharges the pressure
on the pump
5.4.1 Operation without electronic system
monitoring
NOTE
System malfunctions are not automatically detected or
displayed. Monitoring is switched off.
COP = OFF (see section
6.7 Programming- "Changing the
system monitoring")
5.4.2 Operation with electronic system monitoring
If possible, the pressure switch should be installed after the last metering device in the main line. It monitors the pressure build-up In the
system during the CONTACT time. Monitoring is activated.
COP = PS (factory setting: see section 6.7 Programming - "Changing the system monitoring")
Fig. 9
Connection of pneumatic pump PEF-90 with system monitoring
Legend to Figure 9:
1 Pneumatic pump, e.g., PEF-90
2 Air unit
3 3/2 directional control valve
4 IG502-2-E control unit
5 Pressure switch
6 Friction points
7 Metering devices
8 Air supply line
9 Lubrication line

15
6. Operation
6.1 Display and operating unit
The layout of the screen has changed since 2007. For clarification, Table 3 presents the symbols on the new screen next to the labeling on
the old front panel.
Fig. 10
Display and operating unit
Table 3
Display and control elements of control screen
Image
Designation
Function
New screen
Old screen
Three-digit LED display
Values and operating status
PAUSE LED
Pause time
CONTACT LED
Indicates contact time (pump operation)
CS LED
Monitoring of system function via an external cycle switch
PS LED
Monitoring of system function via an external pressure switch
FAULT LED
Alarm
UP or DOWN key
•Switch on the display
•
Display values and parameters
•Set values and parameters
SET key
•Switch between programming mode and display mode
•Confirm values
DK button
•Trigger intermediate lubrication
•Delete fault notification
6.2 Three-digit LED display
The display is off in normal mode. It can be activated by briefly pressing one of the two pushbuttons . Current values and pre-set
parameters are displayed. The display also serves to guide and prompt the operator while programming operating parameters.

16
Table 4
Three-digit LED display
Display
Meaning
Statement
Control function
t= TIMER
PA
= PAUSE
The control unit is functioning as
a timer and is currently in PAUSE
mode
Part of the lubrication cycle
Input value and display value in
hours
c= COUNTER
PA
= PAUSE
The control unit is functioning as
a counter and is currently in
PAUSE mode
Part of the lubrication cycle
The unit counts the pulses from
the external timer and compares
them with the preset values
t= TIMER
CO
= CONTACT
The control unit is functioning as
a timer and is currently in the
pump run time (CONTACT)
Input value and display value in
minutes
c= COUNTER
CO
= CONTACT
The control unit is functioning as
a counter and is currently in a
pump cycle (CONTACT)
CONTACT = time during which
the pump supplies lubricant
Input value and display value in
pulses
C= Cycle
O
= OFF
P= Pressure
Display of the start of the
"Monitoring settings" menu
Monitoring
OFF
The PS and CS monitoring
functions are switched off
No system monitoring
Cycle Switch
Cycle
switch
Cycle switch monitoring is active
The cycle switch is monitored for
signals during the CONTACT time
(the pump run time)
Pressure Switch
Pressure switch
Pressure switch monitoring is
active
The pressure switch is monitored
for signals during the CONTACT
time (the pump run time)
Fault Low Level
Fault becau
se fill level is too low
The minimum fill level has been
reached in the lubricant reservoir
The control unit is currently in
FAULT mode.
The operational sequence has
been stopped.
Fault Cycle Switch
Cycle switch fault
No signal from the cycle switch
during pump run time
The control unit is currently in
FAULT mode.
The operational sequence has
been stopped.
Fault Pressure Switch
Pressure switch fault
No signal from the pressure
switch during pump run time
The control unit is currently in
FAULT mode.
The operational sequence has
been stopped.
Operation Hour Meter
The values shown after this are the number of hours the control
unit has operated.
Fault Hour Meter
The values shown after this are the number of fault hours. This is
the amount of time in which the control unit was operated in
FAULT mode
Block mode
No signal from cycle switch. 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.

17
6.3 Function indication by LEDs
Table 5
Function indication by LEDs
LED
LED lights up = display mode
LED flashes = programming mode
Operating voltage is present on pump unit and control unit, system is
currently in operating status PAUSE
Value for PAUSE can be changed
Operating voltage is present on pump unit and control unit, system is
currently in operating status CONTACT (pump motor ON)
Value for CONTACT can be changed
A cycle switch is used for system monitoring. The monitoring is performed on
the progressive metering device during pump operation (CONTACT)
The monitoring type can be changed or
switched off in programming mode. The
cycle switch is actuated by the piston of
the metering device being monitored.
A pressure switch is used for system monitoring. The monitoring is performed
during pump operation (CONTACT)
The monitoring can be changed or
switched off in programming mode. The
pressure switch is actuated by the
pressure in the main line.
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.
6.4 Pushbutton operation
Table 6
Pushbutton operation
Button
Function
Pressing during PAUSE triggers an intermediate
lubrication
Fault notifications are acknowledged and deleted.
The screen is automatically switched on in display
mode
Call up next parameter in programming mode
Increase displayed value by 1
The screen is automatically switched on in display
mode
Call up next parameter in programming mode
Reduce displayed value by 1
Switch between programming mode and display
mode
Confirm values entered
6.5 External control light: SL
If an external SL control light was installed in the vehicle cab, it
lights up for 3 seconds when the ignition is switched on.
Connection of control light: see section 5. Assembly.

18
6.6 Display mode
Display mode can be identified by the lit-up LED displays. The display does not flash. It is used to query the current settings and operating
parameters.
Always start the display mode by briefly pressing either of the two keys .
Table 7
Display mode
Step
Button
Display
1
Press briefly
The current operating status is shown
Example:
Pause Timer operation
2
Display remaining pause time for current lubrication cycle.
Example:
6.8 h
3
Display pre-set total pause time
Example:
9 h (factory setting)
4
Display pump cycle time
Example:
Timer operation
5
Example: System is currently in the operating status Pause, current
tCO display is not possible
6
Display of the pre-set value
Example:
2.6 min
7
Display system monitoring
8
Monitoring via pressure swi
tch
(factory setting)
or
Monitoring via cycle switch
o
r
Monitoring switched off
9
Operating hours display

19
Table 7
Display mode
Step
Button
Display
10/11
Example:
1st part of total value
Write down.
2nd part of total value
Total
value: 533.8 h
Maximum value: 99999.9 h
12
Display fault hours
13/14
Example:
1st part of total value
Write down.
2nd part of total value
Total value: 33.8
h
Maximum value: 99999.9 h
15
Display clears
Oh and Fh values are stored in EEPROM and cannot be deleted
6.7 Programming
6.7.1 Start programming mode
•Programming mode can be identified by the flashing displays
Table 8
Start programming mode
Step
Button
Display
1
Press longer than 2
s
Display flashes
(code
000 = factory setting)
2
Press briefly
(confirm code
)
Pause in timer operation
"Pause" LED flashes

20
6.7.2 Changing the pause time or pump run time
Table 9
Changing the pause time or pump run time
Step
Button
Display
1
Press longer than 2
s
Display flashes
(code
000 = factory setting)
2
Press briefly
(confirm the code)
Pause in timer operation
"Pause" LED flashes
3
Press briefly
Pause time 9 h
(factory set
ting)
4
Set new value
Example: 6.8
h
5
Press briefly
(confirm the new value)
6
Press briefly
7
8
Press briefly
Confirm new setting
9
Press longer than 2 s
New settings are written to memory
Display clears
6.7.3 Changing the system monitoring
Table 10
Changing the system monitoring
Step
Button
Display
1
Press longer than 2
s
Display flashes
(000 factory set
ting)
2
Press briefly
(confirm code)
Pause in timer operation
"P
ause" LED flashes
3
Press until:
Beginning of monitoring settings is displayed