SKF PSG Series User manual

for oil, grease, and fluid grease, for use in SKF
ProFlex, MultiFlex, and circulating oil centralized lubrication
systems
Modular Feeders of Product Series PSG
EN
Version 01
Component Lifecycle Manual (CLM)
Operating instructions acc. to EC Dir. 94/9/EC (ATEX)

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EN

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Masthead EN
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Masthead
These assembly instructions pursuant to
EC Machinery Directive 2006/42/EC are an
integral part of the product described here
and must be kept for future use.
Warranty
The instructions do not contain any infor-
mation on the warranty. This can be found
in the General Conditions of Sales, which
are available at:
www.skf.com/lubrication.
Copyright / Integration of instructions ©
SKF Lubrication Systems Germany GmbH
All rights reserved.
These instructions are protected by copy-
right.
The use of the contents for the purpose of
integration into the documentation of the
machine manufacturer in whose product it
will be integrated is expressly allowed. This
also includes the preparation of training
documents for internal, non-commercial
purposes. Any other usage of any kind
without written permission of the rights
holder is prohibited and constitutes a viola-
tion of copyright.
Manufacturer and service address
If you have technical questions, please
contact:
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

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Modular Feeders of Product Series PSG 1
Explanation of symbols and signs 7
1. Safety instructions 9
1.1 General safety instructions 9
1.2 General behavior when handling
the product 9
1.3 Qualified technical personnel 10
1.4 Electric shock hazard 10
1.5 System pressure or hydraulic
pressure hazard 10
1.6 Operation 11
1.7 Assembly / maintenance / malfunction
/ decommissioning / disposal 11
1.8 Intended use 12
1.9 Foreseeable misuse 12
1.10 Disclaimer of liability 13
1.11 Explosion protection in ATEX 13
1.12 Referenced documents 14
1.13 Residual risks 15
2. Lubricants 16
2.1 General information 16
2.2 Selection of lubricants 16
2.3 Approved lubricants 17
2.4 Lubricants and the environment 18
2.5 Lubricant hazards 18
3. Overview / functional description 19
3.1 Overview of progressive feeders 19
3.2 Information on volume data 20
3.3 Overview of a general progressive
system 21
3.3.1 Functional description of a general
progressive system 22
3.4 Functioning of a PSG progressive
feeder 23
3.5 Information on the design of a
PSG progressive feeder 24
4. Technical data 25
4.1 PSG1 technical data 25
4.2 PSG2 technical data 28
4.3 PSG3 technical data 30
5. Delivery, returns, and storage 33
5.1 Checking the delivery 33
5.2 Returns 33
5.3 Storage 33
5.3.1 Lubrication units 33
5.3.2 Electronic and electrical devices 33
5.3.3 General notes 33
6. Assembly 34
6.1 Installation information 34
6.2 Installing the PSG1 35
6.2.1 Minimum mounting dimensions/
clearance and tightening torques 35
PSG1 feeder series
6.2.2 PSG1 basic design 36
6.2.3 PSG1 with piston detector (P3) 37
6.2.4 PSG1 with visual cycle indicator (ZY) 38
6.2.5 PSG1 with visual cycle indicator,
housing, and proximity switch (ZS) 39
EN
Table of contents
Table of contents

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PSG1 ATEX feeder series
6.3 PSG1 feeders for ATEX-compliant
applications 40
6.3.1 Information on PSG1 ATEX feeders 41
6.3.2 PSG1 ATEX basic design 43
6.3.3 PSG1 ATEX feeder with plunger rod
and inductive proximity switch 44
PSG2 feeder series
6.4 Installing the PSG2 46
6.4.1 Minimum mounting dimensions/
clearance and tightening torques 46
6.4.2 PSG2 basic design 47
6.4.3 PSG2 with piston detector (P3) 48
6.4.4 PSG2 with visual cycle indicator (ZY) 49
6.4.5 PSG2 with visual cycle indicator,
housing, and proximity switch (ZS) 50
6.4.6 PSG2 with gear-type flow indicator 51
6.4.7 PSG2 with flow limiter for oil
applications 52
6.4.8 PSG2 with flow controller for oil
applications 56
6.4.9 PSG2 with 4/2 directional solenoid
valve for oil applications 57
6.4.10 PSG2 with 2/2 directional solenoid
valve for oil applications 58
PSG2 ATEX feeder series
6.5 PSG2 feeders for ATEX-compliant
applications 59
6.5.1 Information on PSG2 ATEX feeders 60
6.5.2 PSG2 ATEX basic design 62
6.5.3 PSG2 ATEX feeder with
proximity switch 63
6.5.4 PSG2 ATEX feeder with 2/2 directional
solenoid valve and proximity switch 64
PSG3 feeder series
6.6 Installing the PSG3 66
6.6.1 Minimum mounting dimensions/
clearance and tightening torques 66
6.6.2 PSG3 basic design 67
6.6.3 PSG3 with piston detector (P3) 68
6.6.4 PSG3 with visual cycle indicator (ZY) 69
6.6.5 PSG3 with visual cycle indicator,
housing, and proximity switch (ZS) 70
6.6.6 PSG3 with gear-type flow indicator 71
6.6.7 PSG3 with flow limiter for oil
applications 72
6.6.8 PSG3 with flow controller for oil
applications 75
6.6.9 PSG3 with 4/2 directional
solenoid valve for oil applications 76
PSG3 ATEX feeder series
6.7 PSG3 feeders for ATEX-compliant
applications 77
6.7.1 Information on PSG3 ATEX feeders 78
6.7.2 PSG3 ATEX basic design 80
6.7.3 PSG3 ATEX feeder with plunger rod
and inductive proximity switch 81
6.8 Installing a PSG modular feeder 82
6.9 Lubrication line connection 83
6.9.1 Assembly 83
6.9.2 Lubrication line arrangement 84
6.10 Consolidation of outlets 85
6.11 Changing a PSG module 86
6.12 Converting the cycle indicator
(ZY) (PSG1/PSG2) 87
6.13 Converting the piston detector
(P3) (PSG1/PSG2) 88
6.14 Attachment of bridges (crossporting) 89
EN
Table of contents

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6.15 Note on the rating plate 92
7. Commissioning 93
7.1 General information 93
7.2 Commissioning 93
7.2.1 Venting a grease progressive system 93
7.2.2 Venting an oil progressive system 95
8. Operation/decommissioning and disposal 96
8.1 Temporary shutdown 96
8.2 Recommissioning 96
8.3 Decommissioning and disposal 96
9. Maintenance 97
9.1 General information 97
10. Malfunctions, causes, and remedies 98
10.1 Prior to beginning troubleshooting 98
10.2 Feeder and system malfunctions 99
11. Spare parts 102
12. Accessories 111
EN Table of contents

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EN
Possible symbols
Meaning
Note
Electrical component hazard, elec-
tric shock hazard
Slipping hazard
Hazard from hot components
Hazard from hot surface
Risk of being drawn into machinery
Crushing hazard
Danger from suspended load
Pressure injection hazard
Explosion-proof component
Electrostatic sensitive components
Wear personal safety equipment
(goggles)
Secure (lock) the closing device
against accidental starting of the
machine
Environmentally sound disposal
Explanation of symbols and signs
Explanation of symbols and signs
You will find these symbols, which warn of
specific dangers to persons, material assets,
or the environment, next to all safety in-
structions in this lifecycle manual.
Read the instructions completely and follow
all operating instructions and the warning
and safety instructions.
Information symbols within the text
Symbol Meaning
Prompts an action
Used for itemizing
Refers to other facts, causes, or consequences
Provides additional information within procedures
Warning level Consequence Probability
DANGER Death / serious injury Immediate
WARNING Serious injury Possible
CAUTION Minor injury Possible
NOTE Property damage Possible
Symbol

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EN
Instructions placed directly on the product,
such as:
o Arrow indicators
o Fluid connection labels
o Warnings
must be followed and kept in fully
legible condition.
Explanation of symbols and signs
Abbreviations and conversion factors
Abbreviations
°C degrees Celsius sq.in. square inch
s seconds kp kilopond
dB (A) sound pressure level cu.in. cubic inch
i.e. that is mph miles per hour
< less than fpsec feet per second
± plus or minus °F degrees Fahrenheit
> greater than fl.oz. fluid ounce
e.g. for example in. inch
Ø diameter gal. gallon
incl. including
K Kelvin Conversion factors
kg kilogram Length 1 mm = 0.03937 in.
rh relative humidity Area 1 cm² = 0.155 sq.in.
kW kilowatt Volume 1 ml = 0.0352 fl.oz.
l liter 1 l = 2.11416 pints (US)
Min. minute Mass 1 kg = 2.205 lbs
max. maximum 1 g = 0.03527 oz.
min. minimum Density 1 kg/cm³ = 8.3454 lb./gal.
(US)
mm millimeter 1 kg/cm³ = 0.03613 lb./cu.in.
ml milliliter Force 1 N = 0.10197 kp
N Newton Speed 1 m/s = 3.28084 fpsec
Nm Newton meter 1 m/s = 2.23694 mph
oz. ounce Acceleration 1 m/s² = 3.28084 ft./s²
psi pounds per square inch Pressure 1 bar = 14.5 psi
hp horsepower Temperature °C = (°F-32) x 5/9
lb. pound Power 1 kW = 1.34109 hp
sq.in. square inch

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ENEN
1. Safety instructions
1.1 General safety instructions
The operator must ensure that the instruc-
tions are read and fully understood by all
persons tasked with working on the product
or who supervise or instruct such persons.
The instructions must be kept readily available
together with the product.
The manual forms part of the product and
must accompany the product if sold to a
new owner.
The product described here was manufac-
tured according to the state of the art.
Risks may, however, arise from its usage
and may result in personal injury
or damage to property.
Any malfunctions affecting safety must be
remedied immediately.
In addition to the lifecycle manual, all statu-
tory regulations and other regulations for
accident prevention and environmental pro-
tection must be observed.
o The product may only be used in aware-
ness of the potential dangers, in proper
technical condition, and according to the
information in this manual.
o Personnel must familiarize themselves
with the functions and operation of the
product. The specified assembly and op-
erating steps and their sequences must
be observed.
o Any unclear points regarding proper con-
dition or correct assembly/operation must
be clarified. Operation is prohibited until
issues have been clarified.
o Unauthorized persons must be kept away.
o All safety instructions and in-house in-
structions relevant to the particular activity
must be observed.
o Responsibilities for different activities
must be clearly defined
and observed. Uncertainty seriously en-
dangers safety.
o Protective and safety mechanisms can-
not be removed, modified, nor disabled
during operation and must be checked
for proper function and completeness at
regular intervals.
If protective and safety mechanisms must
be removed, they must be installed im-
mediately following conclusion of work
and checked for proper function.
o Any malfunctions that occur must be
resolved according to responsibility. The
supervisor must be notified immediately
in case of malfunctions outside one's indi-
vidual scope of responsibility.
o Wear personal protective equipment.
o Observe the relevant safety data sheets
when handling lubricants/equipment.
1.2 General behavior when handling the product
1. Safety instructions

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ENEN
1.3 Qualified technical personnel
Only qualified technical personnel may install,
operate, maintain, and repair the products
described here.
Such persons are familiar with the relevant
standards, rules, accident prevention regu-
lations, and assembly conditions as a result
of their training, experience, and instruction.
They are qualified to carry out the required
activities and in doing so recognize and
avoid any potential hazards. The definition
of qualified personnel and the prohibition
against employing non-qualified personnel
are laid down in DIN VDE 0105 and
IEC 364. Relevant country-specific defini-
tions of qualified technical personnel apply
for countries outside the scope of
DIN VDE 0105 or IEC 364.
The operator is responsible for assigning
tasks and the area of responsibility.
The personnel must be trained and in-
structed prior to beginning work if they do
not possess the requisite knowledge.
Product training can also be performed by
SKF in exchange for costs incurred.
1.4 Electric shock hazard
WARNING
Electric shock
Assembly, maintenance, and re-
pair work may only be performed
by qualified technical personnel.
De-energize the product prior to
beginning work.
Local conditions for connections
and local regulations (e.g., DIN,
VDE) must be observed.
1.5 System pressure or hydraulic
pressure hazard
WARNING
System pressure
The product described here is
pressurized during operation.
Depressurize the product before
starting any assembly, mainte-
nance, or repair work.
WARNING
Hydraulic pressure
The product described here is
pressurized during operation.
Depressurize the product before
starting any assembly, mainte-
nance, or repair work.
1. Safety instructions