SKF CS200 User manual

CS200 Curve Sensor Controller
CS200-S3
Operating Manual
Version 3

Contents page 1
EN
Imprint
The operating manual is part of the curve
sensor controller CS200(-S3).
The manual has been edited in conformity with
applicable standards and rules for technical
documentation.
© Copyright
SKF LUBRICATION SYSTEMS GERMANY AG
reserves the right to make changes to adapt to
technical improvement. Reprinting or copying
even of parts of this manual requires the
permission of SKF LUBRICATION SYSTEMS
GERMANY AG.
Editor
Dipl.-Ing. S. Waschki
Contents
Information Concerning the
EC Declaration of Conformity............................ 2
Introduction ....................................................... 3
Notes Concerning the
Operating Manual.............................................. 3
Applications....................................................... 4
Scope of Supply................................................ 4
Safety Instructions............................................. 5
Design and Function ......................................... 6
Function........................................................... 6
Design ............................................................. 6
Installation......................................................... 9
Setup ............................................................... 9
Electrical Connection ...................................... 9
Operation ........................................................ 13
Operating Elements ...................................... 13
Parameter Settings for Time-Controlled
Lubrication..................................................... 14
Parameter Settings for Travelling Distance
Controlled Lubrication .................................. 15
Parameter Settings for Curve-Controlled
Lubrication..................................................... 17
Combining the Operating Modes................. 18
Maintenance.................................................... 20
Failures ........................................................... 20
Service ............................................................ 20
Specifications.................................................. 22

Information Concerning the EC Declaration of Conformity page 2
EN
For the product designated below:
Curve sensor controller
Type CS200(-S3)
we herewith certify that it conforms to the
pertinent safety requirements set forth in the
following Council Directive(s) for the
harmonisation of the laws of the Member
States...
Electromagnetic compatibility 89/336/EEC
Notes
(a) This declaration certifies the conformity with
the directives listed, but does not entail an
express assurance of properties.
(b) The safety instructions in the documentation
accompanying the product must be
observed.
(c) Taking into operation of the certified
products is not allowed until evidence has
been provided that the machinery, vehicle
or similar item, into which the product is
integrated, conforms to the regulations and
requirements set forth by the applicable
directives.
(d) The operation of the products on non-
standard line voltage as well as non-
adherence to the installation instructions
can affect the EMC properties and electrical
safety.
If required, you can request the declaration of
conformity or manufacturer’s declaration for this
product from our central contact address.
Information Concerning the EC Declaration of Conformity

Introduction page 3
EN
Introduction
The curve sensor controller CS200(-S3) is a
reliable, technically tried and proven product.
The curve sensor controller CS200(-S3) has
been made in conformity with the generally
recognized technical rules and the applicable
safe working practices as well as the rules for
accident prevention. Still hazards may be
involved in its use, which can lead to injury of
operators or other persons or damage to the
machine or other property.
To ensure trouble-free operation and prevent
hazards, we kindly ask you to read the present
manual carefully and observe the notes
contained in it.
Notes Concerning the
Operating Manual
Text marked with this sign alerts to
special hazards or work that must be
performed with caution.
Use the table of contents to locate the desired
information promptly and successfully.
This operating manual is a part of the system,
and it must be passed on to the company
operating the device upon sale of the system.

Applications page 4
EN
Applications
The curve sensor controller CS200(-S3) -
like all other products of SKF Lubrication
Systems Germany AG - must be used
only as intended and in adherence to the
information contained in the
accompanying operating manual.
We expressly emphasize that dangerous
materials of any type, especially
materials which are classified as
dangerous according to EC directive
67/548/EWG article 2, paragraph 2, may
be stored and transported and/or
distributed with SKF central lubrication
systems and components only after
consulting SKF Lubrication Systems
Germany AG and receiving their written
approval.
None of the products manufactured by
SKF are approved for application in
connection with hot gases, liquefied
gases, gases liquefied under pressure,
steams or fluids that will reach a steam
pressure of more than 0.5 bar above the
normal atmospheric pressure at the
maximum admissible temperature.
The curve sensor controller CS200(-S3) is used
to control central lubrication systems for
lubrication of wheel flanges or rail tops.
Other use or use beyond this purpose is
considered unintended. SKF will not accept
liability for damages resulting from such
unintended use.
Scope of Supply
The curve sensor controller CS200(-S3) is
supplied alone or integrated in a wheel flange
lubrication system. The scope of supply
includes:
curve sensor controller CS200(-S3)
an operating manual

Safety Instructions page 5
EN
Safety Instructions
Please observe the following safety instructions
to ensure trouble-free functioning of the
lubrication system and prevent damage.
The curve sensor controller CS200(-S3)
exclusively serves the purpose of
controlling central lubrication systems
employed in rail vehicles. It is not suitable
to take over safety-related functions or to
detect curves in connection with the
inclination technology. It is likewise not
suitable for application in aviation or for
the purpose of navigation in vehicles of
any type or ships.
Use of lubricants or substances other
than those approved of by SKF in
connection with a SKF central lubrication
system is prohibited.
The system must be disconnected from
the compressed air supply and electric
voltage and depressurized before
undertaking any work on it, e.g. cleaning,
refilling with lubricant, etc.
Do not spray people or animals with
lubricants.
The general rules and safety regulations for
work with compressed air-operated machines,
devices and systems must be observed.
Use the units only in technically perfect
condition for the intended use. Be aware of
hazards and observe the operating manual.
Especially errors that may influence safety must
be resolved immediately.
The safety mechanisms must not be damaged,
dismantled, or in any way made inoperable, nor
must they be replaced by parts which have not
been expressly approved by SKF.
In case of failure, disconnect the unit from the
compressed air supply as soon as possible.
The electrical connection and all interventions
such as repairs, component replacement, etc.
may be carried out only by properly qualified
and instructed personnel.
If devices are improperly connected,
substantial material and personal
damage may be the consequence.
Unauthorised alteration of the device and use of
unapproved spare parts and auxiliaries are not
allowed.
Worn-out systems must be made inoperable
and disposed of properly.

Design and Function page 6
EN
Design and Function
Function
The curve sensor controller CS200(-S3) is used
to control central lubrication systems for
lubrication of wheel flanges or rail tops. The
device controls two spraying nozzles. Control
modes are curve sensor, time or travelling
distance control.
The CS200-S3 is a special version of the curve
sensor controller CS200 and especially meant
for lubrication systems in which all spraying
nozzles in travelling direction are controlled by
only one solenoid valve.
In the time-controlled lubrication mode a
lubrication cycle is triggered after a set pause
time, regardless of the distance travelled.
For travelling distance controlled lubrication the
device features a pulse input allowing it to
receive signals that are proportional to the
distance travelled. A lubrication cycle will be
triggered as soon as a set number of pulses has
been received.
For curve sensor controlled lubrication you can
determine whether the wheel flanges are to be
lubricated on both sides or only on the wheels
lying on the outside of the curve in the direction
of motion.
Additionally, lubrication may pulse operated
while travelling through a curve.
Curves are detected by an integrated sensor
with adjustable sensitivity. Curve controlled
lubrication can be combined with either time or
travelling distance controlled lubrication.
The parameters for the different operating
modes are set at an 8-position DIP switch.
Design
Figure 1 shows the open curve controller
CS200(-S3).
You can see the electrical supply connector (1),
a rotary position switch (2) for sensitivity
adjustment of the curve sensor, the 8-pole DIP-
switch (3) for programming of the unit, a
hardware reset button (4), a push-button (5)
triggering a lubrication and taking over the
parameters set with the selector switches (2 or
3), a cable union M20x1.5 (6) as well as diverse
LEDs (see Figure 2). The protective earth
conductor terminal is identified as position
number (7).

Design and Function page 7
EN
Figure 1. Operating and connecting elements
of CS200 (-S3)
1 Electrical connector
2 Rotary position switch for sensitivity
adjustment of curve sensor
3 DIP-switch for system configuration
4 Hardware reset button
5 DK push-button for manual operation
and takeover of parameters
6 Cable union M20x1.5
7 Protective earth conductor terminal

Design and Function page 8
EN
Figure 2. Overview of LEDs
8 Operating voltage LED, green
9 Valve output 2 (A2), yellow
10 Valve output 1 (A1), yellow
11 Release input (FG), green
12 Direction of motion input (VR), green
13 Pulse input (P), green
14 TXD output (TXD), red
15 RXD input (RXD), green
16 Signal LED 1 (SR), red
17 μC error LED, red
18 Signal LED 2 (SY), yellow
19 Pulse frequency dependent release,
green

Installation page 9
EN
Installation
Setup
The curve sensor controller is installed vertically
with the cable union facing down, install it inside
the vehicle. Avoid installing the device on
vibrating walls or objects.
If the curve control function is not used, the
device may also be installed horizontally, install
it inside the vehicle.
Electrical Connection
The electrical connection of CS200(-S3)
may only be performed by properly
qualified and instructed personnel. The
notes in the operating manual must be
observed.
Connect or repair the device only when
the power supply is switched off. If
required, first connect the protective
earth conductor before beginning work.
Before any work on the opened
controller, briefly touch the housing
ground (e. g. protective earth conductor
terminal inside housing) with hands or
tools, to prevent electrostatic discharge.
The electrical connection is achieved by means
of connector (1). The pin-out of the inputs is
shown in Table 1.
A typical electrical connection diagram is shown
in Figure 3.
Table 1. Pin-out of the electrical connector
Terminal No. Designation Function
8 -P Pulse input IP, negative potential, opto-electrically separated from
operating voltage potential
7 +P
Pulse input IP, positive potential, opto-electrically separated from
operating voltage potential
Connection of an external push-button DK for time or curve controlled
lubrication possible
6 VR Direction of motion input
5 FG Release input
4 A2 Output 2 for spraying valve or additional controller
3 A1 Output 1 for spraying valve or additional controller
2 0 V Negative operating voltage potential
1 +24 V Positive operating voltage potential

Installation page 10
EN
Curve Sensor Controller CS200(-S3)
operation
Electric connecting diagram
halogenfree cable
Figure 3. Electric connecting diagram for CS200(-S3)

Installation page 11
EN
Using the Curve Sensor
When the curve sensor is used, ensure faultless
connection between the outputs A1 and A2 and
the valves Y1 and Y2.
If only the wheels lying on the outside of the
curve are to be lubricated when the vehicle
travels through curves, the direction of motion
input VR must be connected, if the vehicle can
run in two directions. Figure 4 defines the
direction of motion of the vehicle, the curve
directions and the positions of the nozzles.
Table 2 shows the control of the valves Y1 and
Y2 depending on the direction of motion and
curve direction.
If both sides are to be lubricated when the
vehicle travels through curves, the direction of
motion input VR does not need to be
connected, even if the vehicle can travel in two
directions. In this case the outputs A1 and A2
must be connected in parallel outside the
device.
Table 2. Switching mode of outputs A1 and
A2 depending on direction of
motion and curve direction, CS 200
Curve
direction
VR A1 Y1 A2 Y2
right 0 V 24 V 24 V 0 V 0 V
left 0 V 0 V 0 V 24 V 24 V
right 24 V 0 V 0 V 24 V 24 V
left 24 V 24 V 24 V 0 V 0 V
Release Input FG
The input FG is used to release the controller for
triggering of lubrication cycles. Only when 24 V
are applied to the release input FG, lubrication
cycles can be triggered.
The release input FG must not be
permanently connected to a 24 V supply,
because this would allow time-controlled
lubrication cycles even when the vehicle
stands still or is braking. A signal from
the vehicle control system must be
provided for to allows to switch
lubrication on and off depending on the
situation.
Figure 4. Definition of the curve direction
CS200
Figure 5. Definition of the curve direction
CS200-S3
Top view
CS200-S3
Righthand
curve
Lefthand
curve
VR = 24 V
VR = 0 V
Direction of motion 1
Direction of motion 2
Top view
CS200
Righthand
curve
Lefthand
curve
VR = 24 V
VR = 0 V
Direction of motion 1
Direction of motion 2

Installation page 12
EN
CS200-S3
The CS200-S3 is meant for lubrication systems
in which all spraying nozzles for one direction of
motion are supplied by only one solenoid valve.
Operation in two directions of motions is
possible. To allow for this, the current direction
of motion is communicated to the controller via
the input VR (connection 6) as follows:
signal “0” (0V) = direction of motion 1
signal “1” (24V) = direction of motion 2
When the signal is “0”, all curve, travelling
distance or time controlled spraying cycles are
connected to the output A1 (connection 3).
When the signal is “1”, all spraying cycles are
connected to output A2 (connection 4).
Also see Figure 5 and Table 3 on this.
All further functions and properties are identical
with those of CS200.
Table 3. Switching mode of outputs A1 and
A2 depending on direction of
motion and curve direction, CS200-
S3
Curve
direction
VR A1 Y1 A2 Y2
right 0 V 24 V 24 V 0 V 0 V
left 0 V 24 V 24 V 0 V 0 V
right 24 V 0 V 0 V 24 V 24 V
left 24 V 0 V 0 V 24 V 24 V

Operation page 13
EN
Operation
Operating Elements
Table 4 shows an overview of the operating
elements of the curve sensor controller
CS200(-S3).
The 16-position rotary switch is used exclusively
to set the sensitivity of the curve sensor. Note,
that the uneven steps are not shown.
The 8-position DIP switch is used to program all
other device functions.
The DK push-button serves several functions:
First, it can be used to trigger an intermediate
lubrication. To do so, press the DK push-button
once for a short time (< 1 s). The two outputs
A1 and A2 are activated one after the other
thereby.
Second, the DK push-button is used to take
over parameters after the DIP switches have
been set. To do so, press the DK-push-button
briefly after setting the DIP switch (< 1 s).
Finally the DK push-button can be used to vent
the lines, e. g. during initial opration. The
corresponding procedure is shown in Table 5.
Table 4. Operating elements of CS200(-S3)
Illustration Pos. in Figure
1
Designation Function
02
6
4
8
A
C
E
2 Rotary switch Activates curve sensor and sets its
sensitivity,
uneven steps are not shown.
12345678
ON
3 DIP switch Sets the operating mode and all other
functional parameters.
Pos. 1 Set time controlled or travelling
distance controlled lubrication
Pos. 2 Switching mode of outputs
A1 and A2 (see Table 9),
Pos. 3, 4 Set cycle pause times for
curve controlled lubrication,
Pos. 5 - 8 Set pause times or number of
pulses for time controlled or
travelling distance controlled
lubrication
5 DK push-button Manually triggers a lubrication cycle or
takes over parameters after setting of DIP
switches or upon resolving errors.
Table 5. Function sequence for venting of lines (example)
Time DK is pressed Condition Function triggered
1. > 3s
< 3s
< 3s
during normal operation
during the 10 spraying cycles Y1
upon termination of spraying Y1
10 spraying cycles Y1
termination of spraying Y1
10 spraying cycles Y1
2. > 3s
< 3s
< 3s
< 3s
< 3s
after the 10 spraying cycles Y1
after the 10 spraying cycles Y2
during the 10 spraying cycles Y2
upon termination of spraying Y2
during the 10 spraying cycles Y2
10 spraying cycles Y2
10 spraying cycles Y2
termination of spraying Y2
10 spraying cycles Y2
termination of spraying Y2
3. > 3s upon termination of spraying Y2 or
after 10 spraying cycles Y2
Triggers an intermediate lubrication
and switch-over to normal operation.
Note: If the push-button DK is not pressed for a time exceeding 60 s during or after the procedure, the
controller automatically returns to normal operation.

Operation page 14
EN
Parameter Settings for Time-
Controlled Lubrication
To activate the operating mode “time-controlled
lubrication”, set DIP switch No. 1 to position
“OFF”.
In this operating mode, a lubrication is trigged
at fixed time intervals (spraying periods).
The spraying period duration (T) is set with the
DIP switches No. 5 through 8 as outlined in
Table 6.
During a spraying period, a lubrication is first
triggered at output A1 and a little later at output
A2. The spraying duration tsand the pause
between the lubrications at outputs A1 and A2
are set by the factory and cannot be altered.
Once you have set the DIP switch, press
the DK push-button (5) briefly (<1 s) to
confirm the settings. The parameters are
automatically taken over upon each
power-up of the operating voltage.
Table 6. DIP switch settings for time-controlled lubrication
Switch No. 1 2 3 4 5 6 7 8
Operating mode T in s
Time-controlled lubrication OFF OFF OFF OFF OFF off For combination with curve controlled
lubrication refer to Table 9 OFF OFF OFF ON 10
OFF OFF ON OFF 12,5
OFF OFF ON ON 16
OFF ON OFF OFF 20
OFF ON OFF ON 25
OFF ON ON OFF 32
OFF ON ON ON 40
ON OFF OFF OFF 50
ON OFF OFF ON 65
ON OFF ON OFF 80
ON OFF ON ON 100
ON ON OFF OFF 125
ON ON OFF ON 156
ON ON ON OFF 195
ON ON ON ON 244

Operation page 15
EN
Parameter Settings for Travelling
Distance Controlled Lubrication
To activate the operating mode “travelling
distance controlled lubrication”, set DIP switch
No. 1 to position “ON”.
In this operating mode lubrication cycles are
triggered when a defined distance has been
travelled. The distance is adjustable in steps.
Pulse signals proportional to the distance
travelled must be received at input P (+P, -P).
As soon as the preset number of pulses has
been received at input P, a lubrication cycle is
triggered via both outputs A1 and A2, one after
the other. The number of pulses between two
lubrication cycles is set with the DIP switches
No. 5 through 8 as outlined in Table 7. Figure 6
shows a pulse diagram for travelling distance
controlled lubrication.
Once you have set the DIP switches,
press the DK push-button (5) briefly (<1
s) to confirm the settings. The
parameters are automatically taken over
upon each power-up of the operating
voltage.
Table 7. DIP switch settings for travelling distance controlled lubrication
Switch No. 1 2 3 4 5 6 7 8
Operating mode Number of
pulses
ON OFF OFF OFF OFF offTravelling distance controlled
lubrication
For combination with curve controlled
lubrication refer to Table 9 OFF OFF OFF ON 500
OFF OFF ON OFF 750
OFF OFF ON ON 1.125
OFF ON OFF OFF 1.700
OFF ON OFF ON 2.125
OFF ON ON OFF 3.200
OFF ON ON ON 4.800
ON OFF OFF OFF 7.200
ON OFF OFF ON 10.800
ON OFF ON OFF 16.200
ON OFF ON ON 24.300
ON ON OFF OFF 36.450
ON ON OFF ON 54.675
ON ON ON OFF 82.000
ON ON ON ON 123.000

Operation page 16
EN
T
t
s
t
s
t
s
t
s
T
a) Travelling distance controlled lubrication
Release FG
Pulse input P
Spraying output 1 A1
Spraying output 2 A2
b) Time controlled lubrication
Release FG
Spraying output 1 A1
Spraying output 2 A2
Figure 6. Pulse diagram: a) travelling distance controlled lubrication, b) time-controlled
lubrication
(the number of pulses has been reduced for clarity)
ts: Spraying cycle time
T: Spraying period duration
For the time from power-up to the first spraying cycle a random value between
0 and the preset value is selected.

Operation page 17
EN
Parameter Settings for Curve-
Controlled Lubrication
The controller CS200(-S3) features an internal
sensor that directly detects the turning motion of
the vehicle as it travels through a curve.
The curve sensor function is activated/
deactivated with the rotary switch (2). At the
same time, this switch allows to set the
sensitivity of the sensor as outlined in Table 8.
Table 8. Setting the curve sensor
sensitivity
Switch position Sensor sensitivity
0 Curve sensor deactivated
1 approx. 1.9°/s
2 to E intermediate values
F approx. 0.5°/s
Direction of Motion Input VR
Normally, only the wheel running on the outside
of the curve is lubricated during curve-controlled
lubrication. To ensure, the correct spraying
nozzle is activated, the direction of motion input
VR of the controller CS200(-S3) must be
activated, if the vehicle can travel in two
directions and the controller is to control the
lubricating systems on both ends of the vehicle.
Switching Mode of the Outputs while
Travelling through Curves
The switching mode of the sensor outputs A1
and A2 while travelling through curves is set
with the DIP switches No. 2,3, and 4.
DIP switch No. 2 determines, whether or not the
sensor outputs are pulsing while travelling
through a curve. The switch setting is outlined in
Table 9.
If the controller CS200(-S3) is to be used
to control the spraying valves, the
function “cycled outputs” must be
selected.
If the function “cycled outputs” has been
selected, the pause tPA between the spraying
cycles can subsequently be set with one of the
DIP-switches No. 3 and 4
(Table 9).
Figure 7 shows the activation of the outputs A1
and A2 depending on the direction of motion
input VR and the curve directions.
In Fehler! Verweisquelle konnte nicht
gefunden werden. the activation of the outputs
depending on the release input for the direction
of motion and the curve direction in the
operating mode “cycled outputs” is shown.
Once you have set the DIP switches,
press the DK push-button (5) briefly (<1
s) to confirm the settings. The
parameters are automatically taken over
upon each power-up of the operating
voltage.
Table 9. DIP switch settings for curve control controlled lubrication
Switch No. 1 2 3 4 5 6 7 8
Operating mode Switching mode of the
outputs A1 and A2
Cycle pause tPA
during curve, in s
ON Outputs not pulsing
OFF Outputs pulsing OFF OFF 1,5
OFF ON 3
ON OFF 4,5
curve-controlled lubrication
(activated by rotary switch)
Only in combination with
time-controlled or
travelling distance
controlled lubrication,
see Table 6 or Table 7
ON ON 6
Only in combination with time-
controlled or travelling distance
controlled lubrication,
see Table 6 or Table 7

Operation page 18
EN
Combining the Operating Modes
Curve-controlled lubrication can be combined
with either travellng distance controlled or time-
controlled lubrication. To do so, set the
individual parameters as described above.
The controller executes the settings for the
individual operating modes independently of
another. If a curve-dependent lubrication starts
shortly before a lubrication caused by another
operating type, the curve-dependent lubrication
is first performend and then the other
lubrication.
Direction of motion 1 VR
Spraying output 1 A1
Spraying output 2 A2
Curve direction CDIR
Direction of motion 2 VR
Spraying output 1 A1
Spraying output 2 A2
Curve direction CDIR
Figure 7. Curve sensor pulse diagram – outputs not cycled (DIP-switch No. 2 = ON)