SKF LC502 User manual

EN
LC502 control unit for MonoFlex
single-line centralized lubrication systems
1
2
3
Version 02
Operating instructions

Page 2
EN
Operating instructions
1. Display and control elements of
control screen 3
1.1 LC502 control screen 3
2. Display and operating menu 5
2.1 Base menu 5
2.1.1 Main menu 5
2.2 Info - Information mode... 6
   
3. Menu structure 10
3.1 Menu structure of Info 10
   
- View 11
   
- Edit 12
3.4 Menu structure of Status 13
4. LC502 Factory settings on a single-line
centralized lubrication system 14
  
lubrication system 14
   
   
    
   
inputs 20
4.3.1 Control inputs 20
   
    
   
outputs 23
8. Basic settings 44
   
   
   
9. Control ports 47
9.1 KFGL 47
  
plate, 24 VDC 47
9.1.2 KFGL pump for industrial applications,
    
  
12 VDC, 24 VDC 49
9.1.4 KFGL pump for industrial applications
    
230 VAC 50
10. Operational and pump faults 51
10.1 Operational malfunctions 51
10.2 System errors 51
10.3 Display errors 51
   
10.5 Error types 52
   
11. LC502 menu displays 55
12. Technical data for LC502 control unit 61
   
4.5.1 Control outputs 23
5. Options for customer adjustment 24
   
and dwell times... 24
   
pressure build-up and release 26
   
   
    
rotations 30
   
    
6. Options for customer adjustment of a
centralized lubrication system with two
main lines 34
7. Status display 35
7.1 Status - Display of current device
status 35
   
   
  
   
inputs and outputs 41
7.6 IO Conn. - read connection states of
inputs and outputs 42
   
control unit 43

Page 3 EN
1. Display and control elements of control screen
1.1 LC502 control screen
The display and control unit is protected from
water splashes and mechanical damage by
a transparent plastic cover. The cover must
be removed to program the unit and then
remounted afterwards.
LC502 control screen
1
2
3
Display and control elements of control screen
Drawing Description Function
Display  Menu display
 Displays values and parameters
 Error notification
Error LED Displays fault notification
 Red LED flashes = error detected
 Red LED lights up = fault on a signal input, no
error detected on pump control unit (error is outside
pump)
PAUSE LED Indicates pause time
Yellow LED lights up = active pump pause time on at
least one main line
CONTACT LED Indicates contact time (pump operation)
Green LED lights up = active pump runtime
1 = Output 1
2 = Output 2 Indicates pump output 1 to 2
 LED on output 1 or 2 lights up = pump output
1 or 2 is switched on. Lubricant is delivered via the
indicated line (1 or 2)
3 = Inputs Indicates all signal inputs
 LED lights up = signal change on input port The
LED lights up for approx. 1 second each time the
signal on the input port changes.
ENTER key  Confirm selection
 Confirm entry and values
2
1
3
1. Display and control elements of control screen
General notes in documentation
Note
Prompts an action
 
Provides additional information

Page 4
EN
Display and control elements of control screen
Drawing Description Function
Operator keys Operator keys
 Go to menu selection (navigation)
 Edit numerical values
Operator keys Operator keys for menu selection (navigation)
(arrow key up/down/left)
Go to the selected menu based on direction of arrow
Operator keys for changing numerical values
(arrow key up/down)
 The numerical value is incremented/decremented based on direction of arrow.
Press <arrow key right> or <arrow key left> to move the cursor position to the adjacent digit. To exit the
editor window without saving the current change, press the key again after reaching the last digit.
Pressing <arrow key up> increments the selected digit by one.
Pressing <arrow key down> decrements the selected digit by one.
The input value for seconds and minutes can be between 0 and 59; a value between 0 and 65535 can be
programmed for hours.
Operator key for editing numerical values
(arrow key right)
 Pressing the key moves the cursor one position to the right. If the cursor is on the right edge, the edit
window closes and the changes are discarded.
DK key  Pressing triggers an interim lubrication.
 Error notifications are acknowledged and deleted
 Actuations while in configuration mode are ignored.
1. Display and control elements of control screen

Page 5 EN
1
2
3
Device display - Base menu
2.1 Base menu
The control unit's display has three rows of
eight characters each. Only three options are
shown in menu windows containing more than
three available choices. Press the <up/down>
arrow keys to access further options.
Configure a setting on the device involves con-
secutively opening multiple menu windows.
The current device setting is then stored with
a black mark.
Not all possible options are displayed in the
settings. Only settings that are available and
permitted for the selected device type (ProFlex,
MonoFlex, or DuoFlex) and the current device
settings are shown.
The first menu level shows language selection.
The language that is currently selected flashes.
Upon confirmation, the main menu will be dis-
played in the selected language.
2. Display and operating menu
2.1.1 Main menu
The main menu shows the following options:
Device-specific information
Device configuration
Status information
Note
The Service menu selection is
password-protected and can only be
accessed by SKF employees.
2. Display and operating menu
1
2
3
Device display - Main menu

Page 6
EN
Base and main menu
Step Key Display Description
1Entry mask/language selection
The German version is active by default
(flashing).
Press the <arrow key up> to switch to the
English version.
Press the Enter key to confirm.
2Main menu
Service
English
Deutsch
Info
Config
Status
Main menu items
Display Description
Info Display device-specific data such as serial number or firmware
Config.uration Parameter configuration
Status Display current status of control unit
Service Service menu
Menu level only enabled for SKF service personnel
2. Display and operating menu
2.2 Info - Information mode
Information mode is used to query the hard-
ware identification code and the runtimes
stored thus far for the system, motor, and err
time (system runtime, motor runtime, error
time).
Note
No values can be entered or modified
in information mode.
Selection in information mode is per-
formed by briefly pressing one of the
keys.
Display
1
2
3

Page 7 EN
2. Display and operating menu
Information mode
Step Key Display Description
1Entry mask/language selection
The German version is active by default (flashing).
Press “arrow key up” to switch to the English version.
Press the ENTER key.
2Main menu
Press the ENTER key to go to the Info menu.
3Info menu
You can switch between menu items using <arrow key up> and <arrow key down>.
Press the ENTER key to go to the selected sub-menu.
Press the ENTER key.
4Serial
Each control unit has an assigned serial number that can be viewed by pressing the ENTER key.
Firmware
This is the current version number of the software and can be viewed by pressing the ENTER key.
Sys time
This displays the total running time (on-time) of the control unit in hours, minutes, and seconds.
Mot time
This displays the total runtime of the pump motor in hours, minutes, and seconds.
Err time
This displays the total time of the current error (if present). If there is no error, the aggregate time of all
detected errors is displayed.
Press the <arrow key left> to return to the main menu.
Press <arrow key left>.
Mot time
Err time
English
Deutsch
Info
Config
Status
Serial
Firmware
Sys time
Sys time
ØØØØØh
ØØm ØØs
Mot time
ØØØØØh
ØØm ØØs
Err time
ØØØØØh
ØØm ØØs

Page 8
EN
2.3 Config. - Configuration mode
Configuration mode is started by selecting
<Config.> in the main menu and pressing the
ENTER key. The system first queries whether
you want to edit or simply view the configura-
tion data. The password will be queried if you
want to modify the configuration data.
Note
After entering the correct password, all
currently running lubrication proce-
dures are stopped and the configura-
tion mode starts.
If the configuration data will be viewed and
not modified, the Config. menu will appear
upon confirmation by pressing the ENTER key.
No changes can be made in this mode.
Selection in configuration mode is
performed by briefly pressing one of the
keys.
2. Display and operating menu
Configuration menu, Table 1 of 2
Step Key Display Description
1Entry mask/language selection
The German version is active by default (flashing).
Press “arrow key up” to switch to the English
version.
Press the ENTER key.
2Main menu
Select “Config.” using the arrow key.
Press the ENTER key to enter the Config. menu.
3Config. menu
View
Press the ENTER key to enter the configuration
menus. There, you can access configurations for:
System
Settings
Inputs
Outputs
The configuration or selection that is currently
active flashes.
No entries or changes can be made in display
mode.
English
Deutsch
Info
Config
Status
View
Edit

Page 9 EN
2. Display and operating menu
Configuration menu, Table 2 of 2
Step Key Display Description
4Edit
Press the ENTER key to enter the password prompt menu.
Press the ENTER key.
5Password menu
The following password prompt prevents modifications by unauthorized persons.
Press <arrow key up> to increment the number by 1, up to 9.
Press <arrow key down> to decrement the number by 1, down to 0.
Press <arrow key right> to move to the next password number (max. 7).
Press the ENTER key.
Press the ENTER key to enable the following Config. menus.
or:
Press “arrow key left” to cancel entry and return to the main menu.
6Configuration sub-menu selection
Press the ENTER key to enter the Config. menu.
Password
00000000
New Pwd
Outputs
Default
Reset
System
Settings
Inputs
View
Edit

Page 10
EN
Info
Config.
Status
Service
1
2
3
English
Deutsch
Serial
Firmware
Sys time
Mot time
Err time
Sys time
ØØØØØh
ØØm ØØ s
ØØØ-ØØØ-ØØØ-
LØ
v1.Ø.a.1
ØØØØØØØØ
ØØØØ
Mot time
ØØØØØh
ØØm ØØ s
Err time
ØØØØØh
ØØm ØØ s
3. Menu structure
3.1 Menu structure of Info
3. Menu structure

Page 11 EN
Info
Config.
Status
Service
1
2
3
View
Edit
System
Settings
Inputs
Outputs
Pro Flex
Mono Flex
Duo Flex
Line 1
Line 2
Input 1
Input 2
Input 3
None
MCCount
Level SW
Input 4
ExtStop
Output 1
Output 2
ErrorOut
Time
Valves
p-Switch
Pause
Runtime
Dwell time
Pause
ØØØØØh
ØØm ØØs
Release
Buildup
Runtime
ØØØØØh
ØØm ØØs
Agitator
Mechanic
Analogue
None
Input 1
input 2
Dwell time
ØØØØØh
ØØm ØØs
Nonne
Output 2
None
Output 1
Output 2
Release
Buildup
p-switch
External DK
ExtDelay Digital
N Closed
N Open
Inaktiv
Valves
N Closed
N Open
N Closed
N Open
English
Deutsch
None
MCCount.3 (4)
Line 1 (2)
MCCount.2
ØØØØØ
None
Input 3 (4)
MCCount
Delayer
Stopper
Function
Type 1)Polarity2)Function
Polarity3.2 Menu structure of Configurations - View
3. Menu structure
1) The <Type> display menu is only shown (enabled) when
the fill level indicator <Level SW> is activated.
2) The <Polarity> display menu is only shown (enabled)
when the following are activated:
On the monitoring devices' inputs:
1. Extension delay <ExtDelay>
2. Stopper <ExtStop>,
on outputs:
1. Valves <Valve>

Page 12
EN
3.3 Menu structure of Configurations - Edit
3. Menu structure
Passwort
ØØØØØØØØ
Service
1
2
3Pro Flex
Mono Flex
Duo Flex
New Pwd
English
Deutsch
Options for customer adjustment
Cancel
Save
View
Edit
System
Settings
Imputs
Outputs
Default
Reset
Line 1
Line 2
Cancel
Save
Reset
ØØØØØØØØ
Time
Valves
p-switch
Pause
Runtime
Dwell time
Pause
ØØØØØh
ØØm ØØs
Release
Buildup
Runtime
ØØØØØh
ØØm ØØs
None
Input 1
Input 2
Dwell time
ØØØØØh
ØØm ØØs
None
Output 2
None
Output 1
Output 2
Release
Buildup
None
MCCount 3 (4)
Line 1 (2)
MCCount.2
ØØØØØ
None
Input 3 (4)
MC Cycles
Delayer
Stopper
Info
Config.
Status

Page 13 EN
Lub
Errors
IO state
IO conn.
Temp.
Line 1
Line 2
Lubtime
Inputs
Runntime/ Pause
ØØØØØh
ØØm ØØs
Input 1
Input 2
Input 3
Input 4
Output 1 (2)
None3)
1234 M12
0000 000
1234 M12
Temp.
ØØ °C
Info
Config.
Status
Service
1
2
3
Digital
p-switch
RC Ø
Menu pressure switchMC Cycles
EX Ø
RC Ø
Menu machine contactLevel SW
EX Ø
RC Ø
Menu level switchExternal DK
Ø
Menu external pressure contactExtDelay
Ø
Menu pause ExtDelayExtStop
Ø
Menu ExtStopOutput 1
Output 2
English
Deutsch
3.4 Menu structure of Status
3) For a list of possible fault signals <Errors>, see Chapter
10, Operational and pump faults.
3. Menu structure

Page 14
EN
4.1 General design of a single-line cen-
tralized lubrication system
The following description applies to a
single-line centralized lubrication system
for
industrial use with one main line
(line 1).
A changeover valve is flanged
to the KFGL pump housing. Prelubrica-
tion or relubrication distributors can be
used as the single-line distributors.
A pressure switch (<p-switch>) typically
designed as a normally open contact
is located before the last single-line
distributor. The switch closes when the
pre-defined pressure is reached.
Fill level monitoring is performed by a
mechanical fill level switch (W1) located
in the pump reservoir. This switch also
records the rotations of the agitator
(<Agitator>).
The system version is suitable for
greases for greases up to NLGI Grade 2.
4.1.1 System design
See page 15.
Pressure is built up from the pump element (3),
via the changeover valve (7) and the down-
stream main lubrication line (8) to the single-
line distributors (9).
The lubrication procedure on a single-line
centralized lubrication system with prelubrica-
tion distributors is as follows:
The pump feeds lubricant into main line (8)
until all prelubrication distributors (9) have de-
livered their predefined quantity of lubricant to
their lubrication lines (12) and have finished
their changeover procedure. Pressure is then
built up in the main lubrication line (8). The
pressure switch (10) closes once a pre-defined
pressure is reached. The signal to the control
unit is enabled. The control unit pauses the
pump while simultaneously sending a control
signal to the changeover valve (7) via the out-
put assigned to the valve. This valve switches
to pressure release. After pressure release has
been performed, the system is now prepared
for another lubrication cycle.
4. LC502- Factory settings on a single-line centralized lubrication system
The lubrication procedure on a single-line
centralized lubrication system with relubrica-
tion distributors proceeds as follows:
The pump feeds lubricant into the main line
until a pre-defined pressure is attained. The
pressure sensor (10) then closes and sends its
signal to the control unit. The control unit
pauses the pump while simultaneously send-
ing a control signal to the changeover valve (7)
via output 1 assigned to the valve. This valve
switches to pressure release. This lets the re-
lubrication distributors release pressure and
lubricant is delivered to the lubrication lines as
pre-defined. After pressure release has been
performed, the system is now prepared for
another lubrication cycle.
The pump fill level is monitored by a fill level
switch (W1) attached to the agitator. Error no-
tifications can be shown via an external indi-
cator lamp (connected to error output, in ad-
dition to the display).
4. LC502- Factory settings on a single-line centralized lubrication system

Page 15 EN
1
2
3
4. LC502- Factory settings on a single-line centralized lubrication system
Single-line centralized lubrication system with
pressure monitoring
Legend
1KFGL unit
2W1 control with agitator
3Pump element
4LC502 display
5Connector plug for pressure
switch and error output
6230 VAC connector plug
7Changeover valve
8Main lubrication line
9Single-line distributor
10 Pressure switch
11 Pressure gauge (optional)
12 Lubrication lines

Page 16
EN
System inputs, Table 1 of 4
Step Key Display Description
1Select inputs 1 to 4
The Inputs configuration menu is already selected.
Press the ENTER key; you will then enter the following Input menu
Press the ENTER key; you will then enter the following Input 1 menu
or:
You can switch the input menus between input 1 to input 4 using the <arrow keys up/down>.
Select input 2, input 3, or input 4 using <arrow key down>.
Press the ENTER key.
You will then enter the following Function menu.
The types of monitoring and functions that can be assigned to inputs 1 to 4 are listed in the following
Function menu. By default, the inputs and their function are configured as described in Chapter 4.3,
Factory assignment of LC502 control inputs.
Input 1 => <p-switch>,
Input 2 => <Disabled>
Input 3 => <External DK>
Input 4 => <Function> => <Level SW>, type <Agitator>.
4.2 General system inputs on a single-line centralized lubrication system
Inputs
Outputs
Default
Input 4
Input 1
Input 2
Input 3
Function
Type
Polarity
Requirement:
The Configuration menu was pre-selected in the Main menu.
4. LC502- Factory settings on a single-line centralized lubrication system
1
2
3

Page 17 EN
System inputs, Table 2 of 4
Step Key Display Description
2Assign a function to the selected input
The following are available for selection:
Disabled = No monitoring system enabled
MC Count = Machine contact counter (external counter)
Level SW = Pump fill level monitoring (pump reservoir)
p-switch = Pressure switch
Extern DK = External pressure switch contact
Extension delay = Function of an input as pause time extension input
Stopper = Error input (function selection and assignment for the main line that will be stopped in the
event of an error)
Press <arrow key up/down> to assign the function to the selected input.
Press the ENTER key.
Press <arrow key left> to exit the menu.
After making a selection, you will return to the Function menu. Depending on the input assignment,
the Type, Polarity, and p-Active menu items will be enabled in addition to the Function menu item.
2.1 Assign the <Type> switch type and function <Polarity> to the assigned input
You will return to the Function menu. Depending on the function assignment (Step 2), the following
are available:
Function Type Polarity p-Active
Disabled - -
MC Counter - -
Level SW Agitator Agitator rotations (W1) -
Mechanic Mechanical fill level switch N Open/N Closed
Capacitive Capacitive fill level switch -
Analogue Analog fill level switch -
p-switch Analogue Analog pressure switch N Open/N Closed p-Active, see Step 2.4
Digital Digital pressure switch N Open/N Closed
ExternDK - -
ExtDelay - N Open/N Closed
ExtStop - N Open/N Closed
Grenzw.
Disabled
MC Count
Level SW
p-switch
Extern DK
ExtDelay
ExtStop
4. LC502- Factory settings on a single-line centralized lubrication system
Analogue
Digital
Agitator
Mechanic
Capacit.
Function
Type
Polarity

Page 18
EN
System inputs, Table 3 of 4
Step Key Display Description
2.2
or
Assign the <Type> switch type
Select Type using <arrow key down>.
Press the ENTER key.
You will enter the (Sensor) Type menu.
The following are available for selection:
Analogue = Analog fill level sensor, 0-100% display
Digital = Digital input
At Level SW:
Agitator Agitator rotations (in conjunction with mechanical fill level switch)
Mechanic Mechanical fill level switch (W1)
Capacitive Capacitive fill level switch
Select the type using <arrow keys up/down>.
Press <arrow key left> to exit the menu.
2.3 Assign <Polarity> of assigned input
Select Polarity using <arrow key down>.
Press the ENTER key.
You will enter the N Open/N Closed menu.
The following are available for selection:
N Open = Make function in which the contact closes when the switching point is reached.
N Closed = Break function in which the contact opens when the switching point is reached.
Select the type using <arrow keys up/down>.
Press the ENTER key.
Press <arrow key left> to exit the menu.
Function
Polarity
N Open
N Closed
Analogue
Digital
Agitator
Mechanic
Capacit.
Function
Type
Polarity
4. LC502- Factory settings on a single-line centralized lubrication system

Page 19 EN
System inputs, Table 4 of 4
Step Key Display Description
2.4 Configure the <p-Active> analog changeover value of a pressure switch
Select p-Active using <arrow key down>.
Press the ENTER key.
You will enter the menu for the analog changeover value.
Analog inputs can draw a current from 0 to 4 mA. This value range is standardized to that of the
Analog-Digital Converter (ADC), which is between 0 and 1023. For this reason, analog pressure switches
must deliver a current between 0 and 4 mA in order to be correctly evaluated. The changeover value of
analog sensors is evaluated with a hysteresis of 20 ADC steps. The analog changeover value must there-
fore be between 20 and 1003 in order to be correctly processed.
The changeover value (p-Active) can be edited. The modifications will be applied upon confirmation by
pressing the (Enter key).
You can leave the edit window at any time by pressing the left key when the cursor is on the left edge
or pressing the right key when the cursor is on the right edge. The modifications made to the values are
discarded.
Here you can enter:
p-Active = Analog active value (changeover value) on the input
Press <arrow key right> or <arrow key left> to move the cursor position to the adjacent digit. To exit the
editor window without saving the current change, press the key again after reaching the last digit.
To instead apply the current change, press the ENTER key.
Pressing <arrow key up> increments the selected digit by one.
Pressing <arrow key down> decrements the selected digit by one.
Enter the respective changeover value with <arrow keys>; the value must be within the defined setting
range of 20 to 1003.
Press the ENTER key to confirm the entry.
Go to the end of the line using <arrow key right> or <arrow key left> then press the arrow key again
to exit the menu.
Function
Polarity
p-Active
Analogue
Digital
p-Active
ØØØ2Ø
4. LC502- Factory settings on a single-line centralized lubrication system

Page 20
EN
4.3.1 Control inputs
The MonoFlex standard pump contains a
maximum of 4 control inputs.
By default, they are assigned as follows:
Input 1
Pressure monitoring of main line
Pressure in the main line is monitored by a
digital or analog pressure switch installed before
the last single-line distributor. This switch re-
cords the pressure buildup within the main lu-
brication line. After the switching pressure is
attained, the pressure switch sends a switch-
ing signal to the LC502 control unit via input 1
according to its setting as normally open/nor-
mally closed.
<Input 1> => <p-switch>
Input 2-Disabled
This input is used to monitor the pressure in
main line 2 on systems with two main lines.
Input 3
External pressure switch
External pressure switches can be used to
trigger a custom interim lubrication indepen-
dent of the LC502's settings.
<Input 3> => <External DK>
4. LC502- Factory settings on a single-line centralized lubrication system
Input 4
Fill level monitoring of pump reservoir
A fill level switch (W1) on the agitator can con-
trol and monitor the pumps. This switch
counts the rotations of the agitator and sends
this information to the control unit. This allows
the pump runtime to be ended after the pre-
set number of rotations is achieved. On sin-
gle-line centralized lubrication systems, this
switch is used to monitor the fill level of the
lubricant.
<Input 4> => <Function> => <Level SW>,
type <Agitator>
4.3 Factory assignment of LC502 control inputs