SKF LCG2-A Series User manual

EN
Curve Sensor Control Units
of Series LCG2-A/LCG2-B
Operating instructions
Version 05
for the control of centralized lubrication systems in rail vehicles

Page 2
EN Notes
Masthead
These operating instructions pursuant to EC
MachineryDirective 2006/42/EC are an integral
part of the described product and must be
kept for future use.
These operating instructions have been pre-
pared in accordance with the established stan-
dards and rules for technical documentation,
VDI 4500 and EN 292.
© SKF Lubrication Systems Germany GmbH
This documentation is protected by copyright.
SKF Lubrication Systems Germany GmbH re-
serves all rights, including those to the photo-
mechanical reproduction, duplication, and dis-
tribution by means of special procedures (e.g.,
data processing, data media, and data net-
works) of this documentation in whole or in
part.
Subject to changes in contents and technical
information.
Service
If you have technical questions, please contact
the following addresses:
SKF Lubrication Systems Germany GmbH
Berlin Plant
Motzener Strasse 35/37
12277 Berlin
Germany
Tel. [phone]
Fax [phone]
www.skf.com/lubrication
Hockenheim Plant
2. Industriestrasse 4
68766 Hockenheim
Germany
Tel. [phone]
Fax [phone]
www.skf.com/lubrication

Page 3 EN
Table of contents
Table of contents
Information concerning Declaration of
Conformity 4
Explanation of symbols and signs5
1. Safety instructions 6
1.1 Intended use 6
1.2 Authorized personnel 7
1.3 Electric shock hazard 7
1.4 System pressure hazard 7
2. Transport, delivery, and storage 8
2.1 General information 8
2.2 Electronic and electrical devices 8
2.3 General notes 8
3. Overview of device series 10
3.1 Distinguishing features 10
3.2 LCG2-A (24 V DC design) 10
3.3 LCG2-B (72 V DC to 110 V DC design) 12
4. Design and function 14
4.1 Design 14
4.2 Function 16
4.2.1 Curve sensor special mode 17
4.2.2 Curve-dependent spraying/calibration 18
4.2.3 Curve-dependent spraying,
outside curve 19
4.2.4 Curve-dependent spraying,
both sides 19
4.2.5 Setting spray interval time tPfor curve-
dependent spraying 19
4.2.6 Time- or distance-dependent spraying 20
4.2.7 Time-dependent spraying 21
4.2.8 Distance-dependent spraying 22
4.2.9 Setting the spray time tS 23
4.2.10 Setting the pulse voltage range on
LCG2-B 23
4.3 Spray valve actuation based on curve
direction and direction of travel 24
5. Assembly 25
5.1 General information 25
5.2 Setup and installation 25
5.3 Installation of LCG2-A and LCG2-B
curve sensor control units 26
5.3.1 Mounting equipment 26
5.3.2 LCG2-A mounting diagram 27
5.3.3 LCG2-B mounting diagram 28
5.4 Electrical connection 28
5.5 Customer connection of LCG2-A 29
5.6 Customer connection of LCG2-B 30
5.6.2 Electrical connection illustration
LCG2-A01; LCG2-A02; LCG2-A03 31
5.6.3 Electrical connection illustration
LCG2-B01; LCG2-B02; LCG2-B03 33
5.7 Curve function of LCG2-A01/B01
curve sensors 35
5.7.1 Using curve sensor LCG2-A01/ B01 36
5.7.2 Using curve sensor
LCG2-A02/A03/B02/B03 37
6. Operation 38
6.1 Adjustment elements of the curve
sensor control units 38
6.2 Operating modes of curve sensor control
units LCG2-A01, -A02, -B01, -B02 41
6.2.1 Curve-dependent spraying
LCG2-A01, -A02, -B01, -B02 42
6.2.2 Time-dependent spraying
LCG2-A01, -A02, -B01, -B02 43
6.2.3 Time- and curve-dependent spraying
LCG2-A01, -A02, -B01, -B02 44
6.2.4 Distance-dependent spraying
LCG2-A01, -A02, -B01, -B02 45
6.2.5 Distance- and curve-dependent spraying
LCG2-A01, -A02, -B01, -B02 46
6.3 Operating modes of curve sensor
control units LCG2-A03, -B03 47
6.3.1 Curve-dependent spraying 47
6.3.2 Time-dependent spraying 48
6.3.3 Time- and curve-dependent spraying 49
6.3.4 Distance-dependent spraying 50
6.3.5 Distance- and curve-dependent
spraying 51
7. Commissioning 52
7.1 Commissioning procedure 52
8. Decommissioning and disposal 52
8.1 Temporary shutdown 52
8.2 Permanent shutdown 52
9. Maintenance and service 53
10. Operational malfunctions 54
10.1 General information 54
10.2 Troubleshooting 54
11. Technical data 59
11.1 General characteristics 59
11.2 Electrical characteristics 63

Page 4
EN
The product “curve sensor control device” of
the series
is hereby confirmed to comply with the re-
quirements of the following standard:
DIN EN 50155:2008-03
Railway applications - Electronic equipment
used on rolling stock
See the appendix to the Declaration of
Conformity for the operating conditions under
which the product complies with the standard
DIN EN 50155:2008-03.
Notes:
Information concerning Declaration of Conformity
Information concerning Declaration of Conformity
The product is neither designed nor approved
for use in conjunction with fluids of Group 1
(Dangerous Fluids) as defined in Article 2, Para.
2 of Directive 67/548/EEC of June 27, 1967.
The product is neither designed nor approved
for use in conjunction with gases, liquefied gas-
es, pressurized gases in solution, vapors, or
such fluids whose vapor pressure exceeds nor-
mal atmospheric pressure (1013 mbar) by
more than 0.5 bar at their maximum permis-
sible temperature.
When used in conformity with their intended
use, the products supplied by SKF Lubrication
Systems Germany GmbH do not reach the limit
values listed in Article 3, Para. 1, Clauses 1.1 to
1.3 and Para. 2 of Directive 97/23/EC. They are
therefore not subject to the requirements of
Annex 1 of the Directive. Consequently, they do
not bear a CE marking in respect of Directive
97/23/EC. SKF Lubrication Systems Germany
GmbH classifies them according to Article 3,
Para. 3 of the Directive.
The Declaration of Conformity forms part of
the product documentation and is supplied
together with the product.
(a) This declaration certifies compliance with
the aforementioned standards, but does not
constitute a guarantee of characteristics.
(b) The safety instructions in the documenta-
tion included with the product must be
observed.
(c) The commissioning of the products here
certified is prohibited until the machine,
vehicle, or similar in which the product is
installed conforms with the provisions and
requirements of the applicable Directives.
(d) The operation of the products at non-stan-
dard supply voltage, as well as non-adher-
ence to the installation instructions, can
negatively impact the EMC characteristics
and electrical safety.
We further declare:
The aforementioned product is, according
to EC Machinery Directive 2006/42/EC,
Annex II Part B, designed for installation in
machinery/for incorporation with other
machinery to form a machine. Within the
scope of application of the EC Directive,
commissioning shall be prohibited until the
machinery in which this part is installed
conforms with the provisions of this
Directive.
The aforementioned product may, with ref-
erence to EC Directive 97/23/EC concern-
ing pressure equipment, only be used in
accordance with its intended use and in
conformity with the instructions provided
in the documentation. The following must
be observed in this regard:
LCG2-A..., LCG2-B...

Page 5 EN
Indicators used with safety instructions
and their significance
Explanation of symbols
Explanation of symbols and signs


the environment, next to all safety instructions
in these operating instructions.
Please heed these instructions and proceed
with special care in such cases. Please forward
all safety instructions to other users.
Signal word meaning
Danger! Danger of bodily
injury
Warning! Danger of damage to
property and
the environment
Note! Provides additional
information
Instructions placed directly on the machines/
grease lubrication pump units, such as:
Rotation arrows
 
must be followed and kept in fully legible
condition.
You are responsible!
Please read the assembly and operating
instructions thoroughly and follow the safety
instructions.
Hazard symbols
General hazard
DIN 4844-2-W000
Electrical voltage/current
Hot surface
Electrostatic sensitive components
DIN 4844-2-W008
DIN 4844-2-W026
Slipping hazard
DIN 4844-2-W028
Informational symbols
Note
Prompts an action
Used for itemizing
Refers to other facts,
causes, or consequences
Provides additional information
Environmentally correct disposal

Page 6
EN 1. Safety instructions
The operator of the described prod-
uct must ensure that the operating
instructions are read and understood
by all persons responsible for assembly,
operation, maintenance, and repair of
the product. The operating instructions
must be kept readily available.
Note that the operating instructions
form part of the product and must
accompany the product if sold to a new
owner.
1. Safety instructions
In addition to the operating instructions,
statutory regulations and other general
regulations for accident prevention in
the railway sector (railway regulations)
and environmental protection must be
observed and applied.
The described product is manufactured in ac-
cordance with the generally accepted rules and
standards of industry practice and with occu-
pational safety and accident prevention regu-
lations. Risks may, however, arise from its us-
age and may result in physical harm to
persons or damage to other material assets.
Therefore the product may only be used in
proper technical condition and in observance
of the operating instructions. In particular, any
malfunctions which may affect safety must be
remedied immediately.
1.1 Intended use
The LCG2-Axx and LCG2-Bxx curve sensor
control units are used exclusively to control
centralized lubrication systems in rail vehicles.
They are not suitable for handling safety-re-
lated functions or for detecting curves in con-
nection with railway tilting systems. They are
likewise unsuitable for use in aviation systems
or for navigation in any type of vehicle or
ships.
Any other usage is deemed non-compliant
with the intended use.
Hazardous materials of any kind, especially
the materials classified as hazardous by CLP
Regulation EC 1272/2008 may only be used
to fill SKF centralized lubrication systems and
components and deliv-ered and/or distributed
with the same after consulting with and re-
ceiving written approval from SKF.
The described products are neither designed
nor approved for use in conjunction with gas-
es, liquefied gases, pressurized gases in solu-
tion, vapors, or such fluids whose vapor pres-
sure exceeds normal atmospheric pressure
(1013 mbar) by more than 0.5 bar at their
maximum permissible temperature.
Unless specially indicated otherwise, products
from SKF Lubrication Systems Germany
GmbH are not approved for use in potentially
explosive areas as defined in the ATEX
Directive 94/9/EC.

Page 7 EN
1. Safety instructions
1.2 Authorized personnel
Only qualified technical personnel may install,
operate, maintain, and repair the products de-
scribed in the operating instructions. Qualified
technical personnel are persons who have
been trained, assigned, and instructed by the
operator of the final product into which the
described product is incorporated. Such per-
sons are familiar with the relevant standards,
rules, accident prevention regulations, and as-
sembly conditions as a result of their training,
experience, and instruction. They are autho-
rized to identify and perform necessary ac-
tions while avoiding any risks which may arise.
The definition of qualified personnel and the
prohibition against employing non-qualified
personnel are laid down in DIN VDE 0105 and
IEC 364.
1.3 Electric shock hazard
Electrical connections for the described prod-
uct may only be established by qualified and
trained personnel authorized to do so by the
operator in observance of the local electrical
operating conditions and local regulations (e.g.,
DIN, VDE). Serious injury or death and prop-
erty damage may result from improperly con-
nected products.
Danger!
Performing work on an energized
pump or product may result in serious
injury or death.
Assembly, maintenance, and repair
work may only be performed on prod-
ucts that have been de-energized by

supply voltage must be switched off
before opening any of the product's
components.
1.4 System pressure hazard
Danger!
Lubrication systems are pressurized
during operation. Centralized lubrication
systems must therefore be depressur-
ized before starting assembly, main-
tenance or repair work, or any system

Danger!
Do not spray people or animals with
lubricants.

Page 8
EN
2. Transport, delivery, and storage
2. Transport, delivery, and storage
2.1 General information
SKF Lubrication Systems Germany GmbH
products are packaged in accordance with
standard commercial practice according to the
regulations of the recipient's country and DIN
ISO 9001. During transport, safe handling
must be ensured and the product must be
protected from mechanical effects such as im-
pacts. The transport packaging must be
marked "Do not drop!".
There are no restrictions for land, air, or sea
transport.
After receipt of the shipment, the product(s)
must be inspected for damage and for com-
pleteness according to the shipping docu-
ments. The packaging material must be pre-
served until any discrepancies are resolved.
SKF Lubrication Systems Germany GmbH
products are subject to the following storage
conditions:
Ambient conditions: Dry and dust-free
surroundings, storage in well
ventilated dry area
Storage time: Max. 24 months
Permissible humidity: < 65%
Storage temperature: -40 °C to +85 °C
Light: Avoid direct sun or UV exposure
and shield nearby sources of heat
2.3 General notes
The product(s) can be enveloped in plastic
film to provide low-dust storage.
Protect against ground moisture by
storing on a shelf or wooden pallet.
At approx. 6-month intervals: Check for
corrosion. If there are signs of corrosion,
reapply anti-corrosive agents.
2.2 Electronic and electrical devices

Page 9 EN

Page 10
EN 3. Overview
Components of the LCG2-A control unit series, Fig. 1
3. Overview of device series
2
0
E
6
.
.
.
C
.
A
.
8
.
.
.
4
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3.1 Distinguishing features
The major features distinguishing the LCG2-A
and LCG2-B series are operating voltages,
system design, and housing dimensions. Both
series are available in three software versions:
LCG2-A 01
LCG2-A 02
LCG2-A 03
LCG2-B 01
LCG2-B 02
LCG2-B 03
(See Chapter 4.1, Table 1)
The software versions differ in terms of actua-
tion of valve outlets A1 and A2 depending on
the curve direction and direction of travel as
well as in terms of the adjustment options for
spray and interval times (see Chapter 4.2,
Table 2).
3.2 LCG2-A (24 V DC design)
Shown without cover