Lincoln SKF DigitalSuper UFD10 Series User manual

Assembly Instructions
DigitalSuper in the UFD10
and UFD20 series
Minimal quantity lubrication system for internal lubrication
Created on:
21.03.2023
Document no.:
951-170-252-EN
Version:
01
Read these instructions before
installation or start
-up of the
product and keep them readily
available for later consultation!

2
Original EC Declaration of Incorporation in accordance with Directive 2006/42/EC,
Appendix II Part 1 B
The manufacturer hereby declares at its sole responsibility that the partly completed machinery conforms to the essential health and safety requirements
of the Machinery Directive 2006/42/EC, Annex I, marked in the Annex to the EC Declaration of Incorporation as applicable and fulfilled at the time of placing
on the market.
The special technical documents were prepared following Annex VII part B. Upon justifiable request, these special technical documents can be forwarded
electronically to the respective national authorities. The authorized company for the compilation of the technical documentation is the manufacturer.
Designation:
Minimal quantity lubrication systems for internal lubrication
Type / item number:
DigitalSuper / UFD10-1-XXXXXX; UFD20-1-10XXXX
Year of manufacture:
See type plate
Furthermore, the following directives and standards were applied in the respective applicable areas:
2006/42/EC: Machinery Directive
2011/65/EU: RoHS II
2014/30/EU: Electromagnetic Compatibility
EN ISO 12100:2010
EN ISO 4414:2010
EN 60204-1:2018
EN 61000-6-1:2007
EN 61000-6-2:2006
EN 61000-6-3+A1:2011
EN 61000-6-4+A1:2011
EN IEC 63000:2018
The partly completed machinery must not be put into service until it has been established that the machinery into which it is to be incorporated is in
compliance with the provisions of the Machinery Directive 2006/42/EC and all other applicable Directives.
Berlin, 21.03.2023
Jürgen Kreutzkämper
Richard Lindemann
Manager, R&D
Germany
Manager, SE
Berlin
Manufacturer: SKF Lubrication Systems Germany GmbH, Motzener Strasse 35/37, 12277 Berlin, Germany
Original UK Declaration of incorporation according to the Supply of Machinery (Safety)
Regulations 2008 No. 1597 Annex II
The manufacturer hereby declares under sole responsibility that the partly completed machinery complies with the essential health and safety
requirements of UK legislation Supply of Machinery (Safety) Regulations 2008 No. 1597 Annex I, marked in the Annex to the EC Declaration of
Incorporation as applicable and fulfilled at the time of placing on the market.
The special technical documents were prepared following Annex VII part B. Upon justifiable request, these special technical documents can be forwarded
electronically to the respective national authorities. The authorized company for the compilation of the technical documentation is SKF (U.K.) Limited,
2 Canada Close, Banbury, Oxfordshire, OX16 2RT, GBR.
Designation:
Minimal quantity lubrication systems for internal lubrication
Type / item number:
DigitalSuper / UFD10-1-XXXXXX; UFD20-1-10XXXX
Year of manufacture:
See type plate
Furthermore, the following regulations and standards were applied in the respective applicable areas:
Supply of Machinery (Safety) Regulations 2008 No. 1597
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 ISO 12100:2010
EN ISO 4414:2010
EN 60204-1:2018
EN 61000-6-1:2007
EN 61000-6-2:2006
EN 61000-6-3+A1:2011
EN 61000-6-4+A1:2011
EN IEC 63000:2018
The partly completed machinery must not be put into service until it has been established that the machinery into which it is to be incorporated is in
compliance with the provisions of UK legislation Supply of Machinery (Safety) Regulations 2008 No. 1597 and all other applicable Directives.
Berlin, 21.03.2023
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
Appendix to Declaration of Incorporation in accordance with 2006/42/EC, Annex II, No. 1 B
Description of the essential health and safety requirements according to 2006/42/EC, Annex I, which have been applied and fulfilled:
Table 1
Appendix to Declaration of Incorporation
No.:
Essential health and safety requirement
Applicable:
Fulfilled:
1.1
Principles
1.1.2
Principles of safety integration
Yes
Yes
1.1.3
Materials and products
Yes
Not completely
fulfilled
1)
1.1.5
Design of machinery to facilitate its handling
Yes
Yes
1.1.6
Ergonomics
Yes
Not completely
fulfilled
2)
1.2
Control systems
1.2.1
Safety and reliability of control systems
Yes
Yes
1.2.3
Starting
Yes
Yes
1.2.6
Failure of the power supply
Yes
Yes
1.3
Protection against mechanical hazards
1.3.1
Risk of loss of stability
Yes
Yes
1.3.2
Risk of break-up during operation
Yes
Not completely
fulfilled
3)
1.3.4
Risks due to surfaces, edges or angles
Yes
Yes
1.3.7
Risks related to moving parts
Yes
Yes
1.3.9
Risks of uncontrolled movements
Yes
Yes
1.5
Risks due to other hazards
1.5.1
Electricity supply
Yes
Yes
1.5.6
Fire
Yes
Yes
1.5.8
Noise
Yes
Yes
1.5.13
Emissions of hazardous materials and substances
Yes
Yes
1.5.15
Risk of slipping, tripping, or falling
Yes
Yes
1.6
Servicing
1.6.1
Machinery maintenance
Yes
Yes
1.6.2
Access to operating positions and servicing points
Yes
Not completely
fulfilled
4)
1.6.4
Operator interventions
Yes
Yes
1.7
Information
1.7.1
Information and warnings on the machinery
Yes
Yes
1.7.1.1
Information and information devices
Yes
Yes
1.7.2
Warning of residual risks
Yes
Yes
1.7.3
Marking of machinery
Yes
Yes
1.7.4
Operating instructions/assembly instructions
Yes
Yes
1.7.4.1
General principles for the drafting of operating instructions/assembly instructions
Yes
Yes
1.7.4.2
Contents of the operating instructions/assembly instructions
Yes
Yes
1.7.4.3
Sales literature
Yes
Yes
1) The product is designed for operation with non-hazardous media. The owner-operator must check whether the lubricant used has
certain hazardous effects (such as sensitization). The installation of a drip pan could be required.
2) The integrator must ensure that the pump is integrated into the machine in such a way that it can be filled and operated ergonomically.
3) The owner-operator must protect the pump against excessive pressure. For this purpose, a pressure limiting valve with suitable
opening pressure must be provided on each pump element.
4) The integrator must ensure that the pump is integrated into the machine in such a way that it can be operated without danger.

4
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.

5
Table of contents
Masthead ...............................................................................................4
Table of contents..................................................................................5
Safety alerts, visual presentation, and layout.................................7
1. Safety instructions...........................................................................8
1.1 General safety instructions......................................................8
1.2 General electrical safety instructions.....................................8
1.3 General behaviour when handling the product ...................8
1.4 Intended use...............................................................................8
1.5 Persons authorized to use the product.................................8
1.6 Foreseeable misuse ..................................................................9
1.7 Referenced documents ............................................................9
1.8 Prohibition of certain activities ...............................................9
1.9 Painting plastic components and seals .................................9
1.10 Safety markings on the product ..........................................9
1.11 Note on the type plate ...........................................................9
1.12 Notes on CE marking .............................................................9
1.13 Note on Low Voltage Directive.......................................... 10
1.14 Note on Pressure Equipment Directive........................... 10
1.15 Note on UKCA marking.......................................................10
1.16 Note on EAC marking.......................................................... 10
1.17 Note on China RoHS mark................................................. 10
1.18 Emergency shutdown ......................................................... 10
1.19 Assembly, maintenance, fault, repair............................... 10
1.20 First start-up, daily start-up.............................................. 10
1.21 Residual risks........................................................................ 11
2. Lubricants ...................................................................................... 12
2.1 General information............................................................... 12
2.2 Material compatibility ............................................................12
2.3 Temperature characteristics................................................ 12
2.4 Ageing of lubricants ............................................................... 12
2.5 Avoidance of malfunctions and hazards ............................ 12
3. Overview, functional description................................................ 13
3.1 Principle of minimal quantity lubrication........................... 13
3.2 Principle of aerosol action .................................................... 13
3.3 General functioning and structure...................................... 13
3.3.1 Minimal quantity lubrication .................................... 14
3.4 Main components of a UFD minimal quantity lubrication
system .............................................................................................14
3.4.1 Aerosol generator ...................................................... 14
3.4.2 Control unit ................................................................. 14
3.4.3 Communication interface ......................................... 15
3.4.4 Flow sensor.................................................................15
3.4.5 Lubricant level gauge and fill level monitoring..... 15
3.4.6 Main air valve (compressed air connection).......... 15
3.4.7 Pressure gauge .......................................................... 15
3.4.8 Fine filter for compressed air................................... 15
3.4.9 Lubricant drain valve................................................. 15
3.4.10 Pressure limiting valve ........................................... 15
3.5 Version-specific components............................................... 16
3.5.1 PROFIBUS communication interface...................... 16
3.5.2 PROFINET communication interface...................... 18
3.5.3 Automatic filling pump.............................................. 19
3.5.4 Automatically controlled bypass valve – bypass
control.....................................................................................19
3.6 System versions and type identification code................... 21
3.6.1 Minimal quantity lubrication systems with one or
two aerosol generators........................................................22
4. Technical data ............................................................................... 42
4.1 Type identification code.........................................................43
4.1.1 UFD10..........................................................................43
4.1.2 UFD20..........................................................................43
5. Delivery, returns, storage............................................................ 44
5.1 Delivery.....................................................................................44
5.2 Return shipment.....................................................................44
5.3 Storage.....................................................................................44
5.4 Storage temperature range .................................................44
5.5 Storage conditions for products filled with lubricant....... 44
5.5.1 Storage period up to 6 months...............................44
5.5.2 Storage period between 6 and 18 months........... 44
5.5.3 Storage period more than 18 months...................44
5.6 Declaration of decontamination ..........................................44
6. Assembly ........................................................................................ 45
6.1 General.....................................................................................45
6.2 Installation location................................................................45
6.3 Mechanical connection ..........................................................45
6.3.1 Minimum mounting dimensions .............................45
6.4 Tightening torques................................................................. 45
6.5 Assembly holes .......................................................................45
6.5.1 Attachment of the MQL systems.............................46
6.6 Installation dimensions and minimum mounting
dimensions......................................................................................46
6.6.1 MMS UFD10-1-100000 und UFD10-1-101000
.................................................................................................46
6.6.2 MMS UFD10-1-200000 und UFD10-1-201000
.................................................................................................47
6.6.3 MMS UFD10-1-110000 und UFD10-1-111000
.................................................................................................48
6.6.4 MMS UFD10-1-210000 und UFD10-1-211000
.................................................................................................49
6.6.5 MMS UFD20-1-100000 und UFD20-1-101000
.................................................................................................50
6.7 Connection of aerosol lines................................................... 51
6.7.1 General instructions for the connection of the
aerosol lines...........................................................................51
6.7.2 Connecting the aerosol lines to an MQL system
with bypass control...............................................................52
6.7.3 Connection of the aerosol lines to an optional SKF
aerosol monitor (AM1000) .................................................52
6.8 Electrical connection .............................................................. 54
6.8.1 Connector pin assignment for standard
configurations........................................................................54
6.8.2 Possible connections by the customer with UFD10-
1-1XX000 with PROFIBUS................................................. 54
6.8.3 Possible connections by the customer with UFD10-
1-2XX000 with PROFINET ................................................. 55
6.8.4 Possible connections by the customer with UFD10-
1-20000 / UFD10-1-201000........................................... 56
6.8.5 Possible connections by the customer with UFD10-
1-110000 / UFD10-1-111000 ........................................57
6.8.6 Possible connections by the customer with UFD10-
1-210000 / UFD10-1-211000 ........................................58
6.8.7 Possible connections by the customer to an
optional SKF aerosol monitor (AM1000) .........................59
6.9 Pneumatic connection...........................................................60

6
7. Setup and fieldbus configuration on the MQL system...........61
7.1 Adjustment elements.............................................................61
7.1.1 Setting options using DIP switches.........................62
7.1.2 Fieldbus configuration ...............................................65
7.1.3 Factory settings...........................................................66
8. Communication with the machine control ...............................68
8.1 Implementation in the fieldbus system of the machine
control..............................................................................................68
8.1.1 Implementation in a PROFIBUS network...............68
8.1.2 Implementation in a PROFINET system.................68
8.2 Process image of the MQL systems ....................................68
8.2.1 Assignment of the input bytes (IB0 and IB1) - data
from MQL system to machine ............................................69
8.2.2 Assignment of the input words................................70
8.2.3 Assignment of the output bytes (OB0 and OB1) -
data from machine to MQL system ...................................71
9. First start-up .................................................................................74
9.1 Initial filling...............................................................................74
9.1.1 Depressurizing the aerosol generator....................74
9.2 Manual filling ...........................................................................75
9.3 Automatic filling ......................................................................75
9.4 First start-up ...........................................................................75
10. Operation......................................................................................76
10.1 Top up lubricant ...................................................................76
11. Maintenance and repair ............................................................77
11.1 General...................................................................................77
11.2 Refilling lubricant in systems with manual lubricant refill
...........................................................................................................77
11.3 Draining lubricant.................................................................79
12. Cleaning........................................................................................80
12.1 Cleaning agents ....................................................................80
12.2 Exterior cleaning...................................................................80
12.3 Interior cleaning....................................................................80
12.4 Cleaning the fine compressed air filter ............................80
12.5 Cleaning the oil filter............................................................81
13. Faults, causes, and remedies ...................................................82
13.1 Prior to beginning troubleshooting...................................82
13.2 Malfunctions and their resolution .....................................82
13.3 Faults when using MQL systems with bypass control...83
13.4 Fault notification via the LED display ...............................84
13.5 Replacing defective fuses....................................................85
14. Repairs..........................................................................................86
15. Shutdown, disposal ....................................................................86
15.1 Temporary shutdown..........................................................86
15.2 Permanent shutdown, disassembly..................................86
15.3 Disposal..................................................................................86
16. Spare parts ..................................................................................87
17. Appendix.......................................................................................88
17.1 Accessories ............................................................................88
17.2 Cable colors in accordance with IEC 60757....................88
17.3 China RoHS Table ................................................................89

7
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.

8
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
Supply of lubricants.
Spare parts should only be used to replace faulty components
of identical construction.
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

9
during transport, installation, start-up, operation, maintenance,
repair and disassembly.
1.6 Foreseeable misuse
Any usage of the product other than as specified in this manual
is strictly prohibited. Particularly prohibited are:
•Use of non-specified consumables, contaminated lubricants,
or lubricants with air inclusions.
•Use of C3 versions in areas with aggressive, corrosive
substances (e.g., high salt load).
•Use of plastic parts in areas with high exposure to ozone, UV
light, or ionizing radiation.
•Use to supply, convey, or store hazardous substances and
mixtures as defined in the CLP Regulation (EC 1272/2008) or
GHS with acute oral, dermal, or inhalation toxicity or
substances and mixtures that are marked with hazard
pictograms GHS01-GHS06 and GHS08.
•Use to supply, convey, or store Group 1 fluids classified as
hazards as defined in the Pressure Equipment Directive
(2014/68/EU) Article 13 (1) a).
•Use to supply, convey, or store gases, liquefied gases,
dissolved gases, vapors, or fluids whose vapor pressure
exceeds normal atmospheric pressure (1013 mbar) by more
than 0.5 bar at their maximum permissible operating
temperature.
•Use in an explosion protection zone.
•Use without proper securing against excessively high
pressures, in the case of pressurized products.
•Use outside of the technical data and limits specified in this
manual.
1.7 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.
1.8 Prohibition of certain activities
•Replacement of or modifications to the pistons of the pump
elements
•Repairs or modifications to the drive
•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
1.9 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.
1.10 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.
1.11 Note on the type plate
The type plate provides important key data such as designation
and material description (or customer number). To avoid loss of
this data in case the type plate becomes illegible, these
characteristics should be entered in the following table.
•Enter characteristics from type plate in Figure 1 below
Fig. 1
Type plate (example)
Legend to Figure 1:
A Type designation
B Order number
C Power supply
D Serial number
1.12 Notes on CE marking
CE marking is effected following the requirements
of the applied directives requiring a CE marking:
•2014/30/EC Electromagnetic Compatibility

10
•2011/65/EU Directive on the restriction of the use of certain
hazardous substances in electrical and electronic equipment
(RoHS II)
1.13 Note on Low Voltage Directive
The protection objectives of the Low Voltage Directive
2014/35/EU are met in accordance with Annex I, No. 1.5.1 of
the Machinery Directive 2006/42/EC.
1.14 Note on Pressure Equipment
Directive
Due to its performance characteristics, the product does not
reach the limit values defined in Article 4, Paragraph 1,
Subparagraph (a) (ii) and is excluded from the scope of Pressure
Equipment Directive 2014/68/EU in accordance with Article 1,
Paragraph 2 Subparagraph (f).
1.15 Note on UKCA marking
The UKCA conformity marking confirms the
product’s conformity with the applicable legal
provisions of Great Britain.
1.16 Note on EAC marking
The EAC conformity marking confirms the
product’s conformity with the applicable legal
provisions of the Eurasian customs union.
1.17 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).
1.18 Emergency shutdown
This is done by a course of action to be defined by the operator.
1.19 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.
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.
1.20 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

11
1.21 Residual risks
Table 2
Residual risks
Residual risk
Possible in lifecycle
Avoidance / Remedy
Personal injury / property damage due
to falling of hoisted parts
A
B
C
G
H
K
Unauthorized persons must be kept away. Nobody is
allowed to be present below hoisted parts. Lift parts using
suitable and tested lifting gear. Ensure adequate
fastening/securing of the unit (loading capacity).
Personal injury/property damage due to
tilting or falling product due to non-
compliance with specified torques
B
C
G
Adhere to the specified torques. Mount the product only
on components with a sufficient load-carrying capacity. If
no
torques are specified, use those specified for the screw
size for screws of strength class 8.8.
Tearing/damage to lines when installed
on moving machine components
B
If possible, do not perform installation on moving parts. If
this is not possible, use flexible hose lines of a sufficient
length.
Lubrication oil spraying out due to faulty
component fitting / faulty line connection
B
C
D
E
F
G
Tighten all components with the appropriate torques. Use
hydraulic screw unions and lines suitable for the indicated
pressures. These must be checked for proper connection
and for damage prior to commissioning.
Lubricant blockage on tool
G
Check the lubricant holes on the tool for obstructions and
replace the tool if necessary
Environmental contamination by
lubricants and wetted parts
K
Dispose of contaminated parts according to the applicable
legal/company rules.
Overpressure at reservoir, filter, screw
unions, and lines
F
The minimal quantity lubrication system must be
depressurized before maintenance work is performed
Personal injury / property damage due
to spilled, leaked lubricant
B
C
D
F
G
H
K
Exercise caution when filling and when closing the plug
screw of the filler socket. Promptly apply suitable binding
agents and remove the spilled lubricant. Follow
operational instructions for handling the oils and
contaminated parts.
Injuries due to open reservoir
C
D
E
F
G
•Preferably fill via the fill connection.
•Close the lid after filling.
Lifecycle phases: A = Transport, B = Assembly, C = First start-up, D = Operation, E = Cleaning, F = Maintenance, G = Malfunction, repair, H
= Shutdown, K = Disposal

12
2. Lubricants
2.1 General information
Lubricants are selected specifically for the respective
application. The selection is made by the manufacturer or
operator of the machine, preferably together with the lubricant
supplier. Should you have little or no experience with the
selection of lubricants for lubrication systems, please contact us.
We will be pleased to support you in the selection of suitable
lubricants and components for the construction of a lubrication
system optimized for the respective application. Please observe
the following points when selecting/using lubricants. You will
avoid possible downtimes and damages to your machine or the
lubrication system.
2.2 Material compatibility
Lubricants must generally be compatible with the following
materials:
•Plastics: ABS, CR, FPM, NBR, NR, PA, PET, PMMA, POM, PP,
PS, PTFE, PU, PUR
Metal steel, grey iron, brass, copper, aluminium
2.3 Temperature characteristics
The lubricant used must be suitable for the specific ambient
temperature of the product. The viscosity required for proper
operation of the product must not be exceeded in case of low
temperatures nor fall below specification in case of high
temperatures. Specified viscosity, see chapter Technical data.
2.4 Ageing of lubricants
Depending on the experience with the lubricant used, it should
be checked at regular intervals to be determined by the
operator whether the lubricant needs to be replaced due to
ageing processes (bleeding). If there is any doubt as to the
further suitability of the lubricant, it must be replaced before
recommissioning. If you have no experience with the lubricant
used, we recommend testing after only one week.
2.5 Avoidance of malfunctions and
hazards
To avoid malfunctions or hazards, please observe the following:
•When handling lubricants, observe the relevant safety data
sheets (SDS) and hazard designations on the packaging, if
any.
•Due to the large number of additives, individual lubricants
which meet the requirements for pumpability specified in the
instructions may not be suitable for use in centralized
lubrication systems.
•Always use SKF lubrication greases, if possible. These are
optimally suited for use in lubrication systems.
•Do not mix lubricants. This may have unforeseeable effects
on the characteristics and on the usability of the lubricant.
•The ignition temperature of the lubricant must lie at least
50 K over the maximum surface temperature of the
components.

13
3. Overview, functional
description
3.1 Principle of minimal quantity
lubrication
NOTE
For the corresponding overview, see section 3.3.1 Minimal
quantity lubrication
Minimal quantity lubrication (MQL) involves total-loss
lubrication, i.e., the lubricant is almost completely consumed
during machining. so treatment of the lubricant is not required.
The actual lubrication is performed at the friction point
between the tool and in the channels for chip removal. The
lubricating effect is achieved by an aerosol, i.e., droplets of
lubricant finely dispersed in an air flow.
Minimal quantity lubrication provides for effective lubrication
of cutting processes using very small amounts of lubricant. The
arduous task of cleaning and disposing of large amounts of
lubricant and cooling lubricant is greatly simplified or
eliminated.
3.2 Principle of aerosol action
NOTE
For the corresponding overview, see section 3.3.1 Minimal
quantity lubrication
Aerosol is a mixture of air and lubricant in which the air has the
function of transporting the lubricant.
In terms of the size and distribution of lubricant droplets
created, the SKF MQL system described here generates a very
homogeneous aerosol with a droplet size of approx. 0.5 µm.
The lubricant droplets are very light due to their small size,
which in turn results in a very low moment of inertia. These
small droplets of lubricant can be transported over long
stretches through lines and deflections without being deposited.
Transporting the aerosol through rotating spindles and tools
is therefore not difficult for the MQL systems even at very high
rotational speeds, since the effect of centrifugal force on the oil
droplets is very low.
3.3 General functioning and structure
NOTE
For the corresponding overview, see section 3.3.1 Minimal
quantity lubrication
All SKF minimal quantity lubrication systems in the Digital
Super series have the same basic structure and work in the
same way.
Using compressed air, the aerosol produced in the lubricant
reservoir is transported via one or several connected aerosol
line(s) to the transfer point on the machine tool.
The volumetric flow of the aerosol and the composition of the
mixture are adjusted by a lubricant and air valve system
according to the operator's specifications.
To form the aerosol, there must be a difference in pressure
between the inlet pressure and the pressure inside the
reservoir. If the two pressures become similar, an aerosol will
no longer form.
During operation, the pressure differential between the inlet
air pressure and the internal reservoir pressure is measured
and monitored. If, for example, the use of a tool with a very
small cooling duct cross-section causes the difference in
pressure to drop below a certain factory-set value, the
compressed air supply will be interrupted in order to restore the
required pressure differential. Any aerosol already produced
continues to flow away to the lubrication point.
Aerosol generation continues when the differential pressure
rises again. This procedure is known as "cycling" and is audible
during operation.
The minimal quantity lubrication system of the UFD Digital
Super series is available in various different configurations.
The versions differ in the number of aerosol generators, the
communication interface to the machine tool, and the presence
of bypass control and/or an automatic filling pump: see section
3.6 System versions and type identification code.
The Digital Super minimal quantity lubrication system is
controlled via a communication interface to the machine tool,
which is a fieldbus connection configured for either PROFIBUS
or PROFINET (other fieldbus interfaces
are available on request).
The minimal quantity lubrication systems work as slaves on
the fieldbus.
Minimal quantity lubrication systems with a PROFINET
communication interface have a gateway that permits
integration into a PROFINET network.
MQL systems with bypass control (BPC) have an active bypass
control specially designed for demanding drilling tasks, such as
deep-hole drilling with small tool diameters (< 5 mm).
In addition, the MQL systems can be equipped with self-
priming filling pumps.
This pump can be used to top up the stock of lubricant in the
aerosol generator from a refill reservoir provided by the
customer (or an SKF reservoir if requested by the customer).
The pump is switched on and off by the control unit of the MQL
system. There are two ways of activating the pump: either by a
command from the machine tool via PROFIBUS or PROFINET,
or by the control unit's automatic mode. The option to be used
is set manually by means of a DIP switch in the MQL control.

14
3.3.1 Minimal quantity lubrication
Fig. 2
Minimal quantity lubrication
Legend to Figure 2:
A Aerosol line
B Compressed air feed
C Fieldbus
D Machine control unit
E Tool
F Tool spindle
G Ball valve
3.4 Main components of a UFD minimal
quantity lubrication system
NOTE
The overview of the main components described in the
following is shown in the relevant graphics in section
3.6.1
Minimal quantity lubrication syst
ems with one or two
aerosol generators
3.4.1 Aerosol generator
The core component of the SKF MQL system is the aerosol
generator, which consists of a number of air and lubricant
nozzles. The nozzles are built into a reservoir that provides both
storage of the required lubricant and also a receptacle for the
generated aerosol.
Depending on the system version, the MQL system has one
aerosol generator (UFD10) or two aerosol generators (UFD20).
3.4.2 Control unit
The MQL system is controlled and monitored by an integrated
control unit. Each aerosol generator has its own control unit
(this means that the UFD20 has two control units).
The following are controlled:
•The main air valve
•The aerosol density

15
•The aerosol flow rate
•The required differential pressure in the aerosol generator
•An optional refill pump
•An additional valve which may be present, and a ball valve to
shut off the aerosol lines
The following are monitored:
•Fill level in the lubricant reservoir
•The inlet air pressure
•The differential pressure between the inlet air pressure and
the pressure inside the reservoir ("internal reservoir
pressure")
•The lubricant flow
•The running time of an optional filling pump
•The functioning of the electrical sensors (the aerosol density
is not monitored)
•The aerosol density values from the optionally available
AM1000 are transmitted via the control to the machine tool
control, where they can be processed
The MQL control unit can exchange data with the machine tool
control via a FIELDBUS interface. In one direction, information
about the status of the MQL system is sent to the machine tool.
In the other direction, all the parameters required for the
control of the lubrication process are sent to the MQL control
unit.
Depending on the system selected, the data can be exchanged
via a PROFIBUS interface or a PROFINET interface. All versions
of the Digital Super systems require only one interface
connection.
3.4.3 Communication interface
The Digital Super minimal quantity lubrication system is
controlled via a communication interface to the machine tool.
This interface is configured as a fieldbus connection for
PROFIBUS or PROFINET (other fieldbus types are available on
request).
Section 3.5 Version-specific componentsdescribes the
PROFIBUS communication interface, and section 3.5.2
PROFINET communication interfacedescribes the PROFINET
communication interface.
3.4.4 Flow sensor
An electronic flow sensor is installed in the lubricant feed to the
aerosol generator, in order to monitor the lubricant flow
during aerosol generation.
The signal from the flow sensor can be processed by the
machine tool control by means of a bit in the process image.
3.4.5 Lubricant level gauge and fill level
monitoring
The lubricant level in the reservoir is continuously monitored by
the control unit using a filling level sensor.
In addition to this, on the UFD10 system, the fill level can be
viewed directly on a visual level gauge on the front of the
control cabinet.
On type UFD20, the visual fill level indicators are located on
the left and right sides of the control cabinet.
3.4.6 Main air valve (compressed air
connection)
The main air valve is fitted directly after the compressed air
inlet and separates all the downstream system components
from the compressed air supply. No aerosol is produced when
the main air valve is closed.
The main air valve is not suitable for controlling aerosol
generation during the machining process. It is to be used only
for opening and closing the compressed air supply at the start
and end of system use.
Interruption of aerosol generation during the machining
process should be done by selecting lube routine number "0".
3.4.7 Pressure gauge
For each aerosol generator in the system, two pressure gauges
are installed in the control cabinet door.
The pressure gauge designated "Air" indicates the inlet air
pressure and the gauge designated "Aerosol" indicates the
internal reservoir pressure.
If the MQL system cycles during operation (see section 3.3
General functioning and structure), the pointer of the "Aerosol"
pressure gauge swings between two values. This swinging
indication is system-inherent and does not indicate a fault.
3.4.8 Fine filter for compressed air
The compressed air supply of the system is equipped with a fine
air filter that ensures the necessary cleanliness of the air for
aerosol generation and separates any humidity from the
compressed air.
3.4.9 Lubricant drain valve
The lubricant in the reservoir can be drained through the
lubricant drain valve. The lubricant drain valve is actuated
manually. See section 11. Maintenance and repairfor further
information on draining the lubricant.
3.4.10 Pressure limiting valve
To protect the aerosol generator from excessive rises in
pressure, an automatic pressure limiting valve is fitted on the
top of the unit in all versions of the system.

16
3.5 Version-specific components
3.5.1 PROFIBUS communication interface
Fig. 3
fieldbus coupler
Legends to Figure 3:
Table 3
LED
H1
Green LED (PROFIBUS)
H2
Red LED (PROFIBUS)
H3
Green LED (MQL)
H4
Red LED (MQL)
Table 4
Plug
Function
H1/H2
Indicates the status of the connection to
the PROFIBUS
H3/H4
Indicates the status of the connection to
the MQL control
1
M12x1 connection to MQL system
2
Fastening screw
3
Union nut
4
M12x1 PROFIBUS connection
5
Terminating resistor
6
M12x1 connection for terminating resistor
Table 5
Plug contact
Assignment
M12x1 plug, B-coded
1
NC
2
BUS-N=A
3
BUS nc
4
BUS-N=B
5
Shield
NOTE
When de-energized, all the LEDs are transparent. The
diagram shows fault-free operation.
MQL systems with PROFIBUS interface have a PROFIBUS
fieldbus coupler (Fig. 3). The MQL system appears on the bus as
an I/O device. Data is exchanged via input and output bytes.
For unique identification of the MQL system on the
PROFIBUS, the bus address must be set. The address is set with
the decimal rotary switches on the respective control unit: see
section 7. Setup and fieldbus configuration on the MQL system.
For diagnostic purposes, the PROFIBUS DP fieldbus coupler has
four LEDs, which provide information about the established data
connection (during start-up or in the event of faults): see
section 3.5.1.1 Connection states.

17
3.5.1.1 Connection states
Table 6
Connection states
Connection to bus
Connection to the MQL control
unit
Status / cause
H1
green LED
H2
red LED
H3
green LED
H4
red LED
Off
Off
Off
Off
Power supply not present
Flashing
Flashing
Flashing
Flashing
Fieldbus coupler is conducting self-test
Flashing
Off
Fieldbus coupler is waiting for the MQL system to send its
configuration data (number of input/output bytes, number of
parameter bytes, data transfer rate, etc.)
On
Off
Connection to MQL system is operating normally
Off
Flashing
Fault: can be resolved, e.g., connection to MQL system is down
Off
On
Fault: cannot be resolved, e.g., faulty checksum in the flash
memory; the fieldbus coupler must be replaced
On
Off
Normal data communication (data exchange)
On
Flashing
Fault: fieldbus coupler is ready to operate but is not addressed
by the bus master, or the configuration sent by the bus master
does not match the configuration of the MQL system. This
prevents the system from starting, if a unit that differs from the
one configured in the bus master is connected.
Flashing
On
Fault: The parameters received from the bus master have a
faulty format, e.g., wrong length or inconsistent content. The
data will not be passed on.
Off
On
Fault: Fieldbus coupler receives no data from the bus during the
monitoring time, e.g., because the data connection was
interrupted. The monitoring time is set by the bus master.

18
3.5.2 PROFINET communication interface
Fig. 4
PROXY connections
MQL systems in the UFD10-1-2XX000 versions can be
operated on a PROFINET I/O controller using a gateway. The
gateway is installed either in a separate switch box or in the
bypass control switch box. On the PROFINET side, the gateway
functions as a typical IO device. The process data of the DP
slaves (MQL system with fieldbus plug) is imaged 1:1 by the
PROFINET IO device. This means that everything in these
instructions regarding communication via PROFIBUS applies
equally to communication via PROFINET.
For diagnostic purposes, the gateway has five LEDs, which
provide information about the established data connection
(during start-up or in the event of faults): see section 3.5.2.1
PROXY connection states.
The colors of the LEDs as shown in Fig. 4 indicate fault-free
operation.
3.5.2.1 PROXY connection states
Table 7
System LEDs
LED
Duo LED
LED color
Status
Meaning
SYS
green
On
Firmware was started
yellow
On
This status should only occur briefly.
If the LED stays yellow continuously, there could be a fault in
the hardware.
green / yellow
Flashing
Bootloader is active
transparent
Off
No operating voltage, or there is a fault in the hardware
APL
green
On
The communication on X2 (PROFIBUS) and X3 (PROFINET) is
in cyclical data exchange and the gateway function is being
executed
green
Flashing with 2.0 s off, 0.5 s on
The gateway has been initialized, but the communication on
X2 (PROFIBUS) is not in cyclical data exchange
red
Flashing with 2.0 s off, 0.5 s on
The gateway has been initialized, but the configuration for the
protocol on X2 (PROFIBUS) is missing or the configuration
contains an error
red
Flashing with 2.0 s off, 0.5 s on, 0.5 s
off, 0.5
s on
The gateway has been initialized, but the configuration for the
protocol on X3 (PROFINET) is missing or the configuration
contains an error
red
On
The gateway has identified one of the following faults during
initialization:
no configuration, faulty configuration, or internal error

19
Table 8
LEDs for PROFIBUS DP master
LED
Duo LED
LED color
Status
Meaning
COM
green
Non-cyclical flashing
No configuration or stack error
green
Cyclical flashing
PROFIBUS has been configured, but bus communication is not
yet approved by the application
green
On
Communication established to all slaves
red
Cyclical flashing
Communication with at least one slave interrupted
red
On
Communication with one or all slaves interrupted
Table 9
LEDs for PROFINET RT IO device
LED
Duo LED
LED color
Status
Meaning
SF
red
On
Watchdog time-out; channel diagnosis, generic diagnosis, or
expanded diagnosis is present; system error
red
At 2 Hz, 3 sec. long
DCP signal service triggered via the bus
transparent
Off
No error
Table 10
LEDs for PROFINET RT IO device
LED
Duo LED
LED color
Status
Meaning
BF5
red
On
No configuration, or slow physical connection, or no physical
connection
red
Flashing cyclically at 2 Hz
No data exchange
transparent
Off
No error
3.5.3 Automatic filling pump
NOTE
See also section 3.6 System versions and type identification
code
The MQL systems can be equipped with a self-priming filling
pump.
This pump can be used to top up the stock of lubricant in the
aerosol generator from a refill reservoir provided by the
customer (or an SKF reservoir if requested by the customer).
The pump is switched on and off by the control unit of the MQL
system. There are two ways of activating the pump: either by a
command from the machine tool via PROFIBUS or PROFINET,
or by the control unit's automatic mode.
The option to be used is set manually by means of a DIP
switch in the MQL control.
3.5.4 Automatically controlled bypass valve –
bypass control
3.5.4.1 Usage and functional description
NOTE
For the corresponding overviews, see section 3.6.1 Minimal
quantity lubrication systems with one or two aerosol
generators"UFD10-1-1100000" and "UFD10-1-210000"
For drilling tasks with increasing drilling depth, it becomes more
difficult to transport the required volume of lubricant to the
cutting edges of the tool, as the increasing depth of the hole
inhibits the flow of the aerosol. At the same time, a decrease in
the air flow rate results in a decrease in aerosol generation, due
to unfavorable internal pressure ratios. Active bypass valve
control is used to counteract this.
For this purpose, a Y-piece divides the aerosol flow at the end
of the aerosol line, as close as possible to the tool spindle. One
part of the divided aerosol flow is directed to the tool via the
spindle, and the other part is directed through the bypass valve

20
either back into the refill reservoir or into the customer's
exhaust air system.
During operation, the bypass valve is opened and closed
according to the pressure conditions prevailing in the MQL
system. The process results in consistently high generation and
supply of aerosol to the tool throughout
the entire drilling process.
To activate the controlled bypass (bypass valve), lube routine
number 50 must be used.
The greatest aerosol volume on the tool is achieved with the
maximum permissible inlet pressure of 10 bar.
The automatic control of the bypass valve results in increased
aerosol volume and constancy of aerosol flow during machining
with tools that generate an unfavorable pressure ratio in the
aerosol reservoir (such as those with small diameters < 5 mm).
The usable signals are provided by pressure sensors (P1 / P2)
integrated into the UFD10-X-1XXXX.
The bypass valve is controlled independently and does not
impair the control of the MQL system.
If a ball valve is used (UFZ.U00-128, section 17.1
Accessories) as the bypass valve, it has its own pneumatic
supply line for pilot control.
In the de-energized state, outlet port 2 is pressurized, which
causes the directional-control ball valve to close.
3.5.4.2 Information display and operation
NOTICE
Control
Errors due to modifications to the bypass control
Do not press the cursor keys or the OK key!
Use the ESC key only in conjunction with the key "▲".
Fig. 5
Display UFD10-1-21x000
The screen on the bypass control is provided for the display of
status messages. It provides current information about the
pressure ratios in the system.
The cursor keys, the ESC key, and the OK key are not
intended for programming input or modifications by the user.
Modifications to the bypass control are normally not
necessary, and should be carried out for special applications
only with the assistance of SKF application specialists.
If any of these keys are pressed accidentally, the cursor key
"▲" should be pressed, followed by the "ESC" key. The control
will then go back to its previous state.
The control unit for the bypass valve has an information
display screen that provides information about the pressure
ratios in the system.
When the operating voltage is switched on, the start screen
appears on the information display for 5 seconds. Then,
information about the inlet pressure (Inlet) and the internal
pressure inside the aerosol reservoir (Tank) is displayed. The
process pressures are displayed only after the main air valve is
activated. The pressures are displayed in bar.
The function keys F1 and F4 on the information display can
be pressed to view a total of 4 displays with the following
information:
Fig. 6
Menu
Display 1:
Inlet pressure and internal pressure in the aerosol reservoir in
bar
Display 2:
Bar graph of inlet pressure and internal pressure in the aerosol
reservoir
Display 3:
Pressure differential between inlet pressure and internal
pressure in the aerosol reservoir
Display 4:
The set pressure values at which the bypass valve will be
activated.
Pressing the F4 function key takes you to the next view. F1
takes you back to the previous view.