SKF UFD20 Series User manual

Version 06
951-170-218-EN
EN
Assembly instructions
acc. to Machinery Directive 2006/42/EC
DigitalSuper
of series UFD10 and UFD20
Minimal quantity lubrication system for internal lubrication

EC Declaration of Incorporation acc. to Machinery Directive 2006/42/EC, Appendix II Part 1 B
The manufacturer, SKF Lubrication Systems Germany GmbH, Berlin Plant, Motzener Straße 35 -37, DE - 12277 Berlin, hereby declares conformity of the
partly completed machinery
Designation: Minimal Quantity Lubrication Systems for Internal Lubrication
Type: DigitalSuper
Item number: UFD10-1-XXXXXX; UFD20-1-10XXXX
Year of manufacture: See rating plate
with the essential protection requirements of Machinery Directive 2006/42/EC at the time of placing on the market.
1.1.2 · 1.1.3 · 1.3.2 · 1.3.4 · 1.5.1 · 1.5.6· 1.5.8 · 1.5.9 · 1.6.1 · 1.7.1 · 1.7.3 · 1.7.4
The technical documentation described in Annex VII, Part B of this Directive has been prepared. We undertake to transmit, in response to a reasoned request
by the national authorities, the special documents for this partly completed machine. The Head of Technical Standards is the authorized representative for
the technical documentation. See the manufacturer information for the address.
Furthermore, the following Directives and (harmonized) standards were applied in the applicable areas:
2011/65/EU RoHS II
2014/30/EU Electromagnetic Compatibility | Industry
Standard Edition Standard Edition Standard Edition Standard Edition
DIN EN ISO 12100 2013 DIN EN 60947-5-1 2010 DIN EN 61000-6-2 2006 DIN EN 61000-6-4 2011
DIN EN 809 2012 DIN EN 61131-2 2008 Correction 2011 DIN EN 60947-5-1 2010
DIN EN 60204-1 2007 Correction 2009 DIN EN 61000-6-3 2011
Correction 2010 DIN EN 60034-1 2015 Correction 2012
DIN EN 50581 2013 DIN EN 61000-6-1 2007
The partially completed machinery must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with
the provisions of Machinery Directive 2006/42/EC and all other applicable Directives.
Berlin, September 30, 2016
Jürgen Kreutzkämper
Manager R&D Germany
SKF Lubrication Business Unit
Dr.-Ing. Holger Schmidt
Manager Development Center Berlin
Lubrication Business Unit
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EC Declaration of Incorporation

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Masthead
Training
SKF conducts detailed training in order to
enable the maximum safety and efficiency.
SKF recommends taking advantage of this
training. For information, contact the rel-
evant SKF service address.
Copyright
© Copyright SKF
All rights reserved.
Warranty
The instructions do not contain any infor-
mation on the warranty. This can be found in
our General Terms and Conditions.
Disclaimer of liability
The manufacturer shall not be held liable for
damage resulting from:
○Improper usage, assembly, operation,
configuration, maintenance, repair, or
accidents
○Improper reaction to malfunctions
○Unauthorized modifications to the
product
○Intentional or gross negligence
○Use of non-original SKF spare parts
The maximum liability for loss or damage
resulting from the use of our products is
limited to the purchase price. Liability for
indirect damage of any kind is excluded.
Masthead
Manufacturer
SKF Lubrication Systems Germany GmbH
Addresses of manufacturer plants
Headquarters
Walldorf Plant
Heinrich-Hertz-Str. 2-8
69190 Walldorf
Germany
Tel: [phone]
Fax: [phone]
Berlin Plant
Motzener Straße 35/37
12277 Berlin
Germany
Tel. [phone]
Fax [phone]
Hockenheim Plant
2. Industriestraße 4
68766 Hockenheim
Germany
Tel. [phone]
Fax [phone]
E-mail: Lubrication-german[email protected]om
www.skf.com/lubrication

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EN Table of contents
Table of contents
EC Declaration of Incorporation ..........................................................................2
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 Intended use ..........................................................................................10
1.4 Foreseeable misuse ..............................................................................10
1.5 Modifications to the product ................................................................11
1.6 Inspections prior to delivery ................................................................11
1.7 Referenced documents ........................................................................11
1.8 Notes on the rating plate .....................................................................11
1.9 Note on CE marking .............................................................................12
1.10 Persons authorized to use the product ..............................................12
1.10.1 Operator ...........................................................................................12
1.10.2 Qualified mechanic .........................................................................12
1.10.3 Qualified electrician ........................................................................12
1.11 Instruction of outside fitters ................................................................12
1.12 Provision of personal protective gear .................................................13
1.13 Operation ...............................................................................................13
1.14 Emergency shutdown ..........................................................................13
1.15 Transport, assembly, maintenance, malfunction,
repair, shutdown, disposal ...................................................................13
1.16 Initial commissioning, daily startup ....................................................15
1.17 Cleaning .................................................................................................15
1.18 Residual risks ........................................................................................16
2. Lubricants .......................................................................... 18
2.1 General information .............................................................................18
2.2 Selection of lubricants ..........................................................................18
2.3 Material compatibility ...........................................................................19
2.4 Aging of lubricants ................................................................................19
3. Overview, functional description .......................................... 20
3.1 Principle of minimal quantity lubrication ...........................................20
3.2 Principle of aerosol action ...................................................................20
3.3 General function and design ...............................................................20
3.4 Main components of a UFD minimal quantity lubrication system..22
3.4.1 Aerosol generator ..........................................................................22
3.4.2 Control unit ......................................................................................23
3.4.3 Communication interface ..............................................................24
3.4.4 Flow sensor .....................................................................................24
3.4.5 Fill level indicator and monitoring ................................................24
3.4.6 Main air valve (compressed air connection) ................................24
3.4.7 Pressure gauge ...............................................................................25
3.4.8 Fine filter for compressed air ........................................................25
3.4.9 Lubricant drain valve ......................................................................25
3.4.10 Safety valve .....................................................................................25
3.5 Design-specific components ...............................................................26
3.5.1 PROFIBUS communication interface ...........................................26
3.5.2 PROFINET communication interface ...........................................29
3.5.3 Automatic filling pump ...................................................................32
3.5.4 Automatically controlled bypass valve – bypass control ............32
3.6 System designs and type codes .........................................................35
3.6.1 Minimal quantity lubrication systems with
one aerosol generator ....................................................................38
3.6.2 Minimal quantity lubrication systems with
two aerosol generators ..................................................................54

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Table of contents
4. Technical data ..................................................................... 58
4.1 General technical data ..........................................................................58
5. Delivery, returns, storage .................................................... 60
5.1 Delivery ..................................................................................................60
5.2 Return shipment ...................................................................................60
5.3 Storage ...................................................................................................60
6. Assembly ............................................................................ 61
6.1 General information .............................................................................61
6.2 Assembly location .................................................................................61
6.3 Mechanical connection .........................................................................62
6.3.1 Minimum mounting dimensions ..................................................62
6.4 Tightening torques ...............................................................................62
6.5 Assembly holes .....................................................................................62
6.5.1 Attaching MQL systems .................................................................63
6.6 Minimum installation and mounting dimensions ............................64
6.6.1 MQL UFD10-1-100000 and UFD10-1-101000 ......................64
6.6.2 MQL UFD10-1-200000 and UFD10-1-201000 ......................65
6.6.3 MQL UFD10-1-110000 and UFD10-1-111000 ......................66
6.6.4 MQL UFD10-1-210000 and UFD10-1-211000 ......................67
6.6.5 MQL UFD20-1-100000 and UFD20-1-101000 ......................68
6.7 Connection of aerosol lines .................................................................69
6.7.1 General notes on the connection of aerosol lines .......................69
6.7.2 Connection of aerosol lines to an MQL system
with bypass control .........................................................................72
6.7.3 Connection of aerosol lines to an optional
SKF aerosol monitor (AM1000) ....................................................74
6.8 Electrical connection ............................................................................75
6.8.1 Connector pin assignment on standard designs.........................76
Customer connectivity for
6.8.2 UFD10-1-1XX000 with PROFIBUS ..................................................78
6.8.3 UFD10-1-2XX000 with PROFINET ...................................................79
6.8.4 UFD10-1-20000 / UFD10-1-201000.............................................80
6.8.5 UFD10-1-110000 / UFD10-1-111000 ..........................................81
6.8.6 UFD10-1-210000 / UFD10-1-211000 ..........................................82
6.8.7 Customer connectivity with an optional SKF
aerosol monitor (AM1000) ..................................................................83
6.9 Pneumatic connection .........................................................................84
7. Setup and fieldbus configuration on MQL system ................. 85
7.1 Adjustment elements ...........................................................................85
7.1.1 Setting options via DIP switches .........................................................86
7.1.2 Fieldbus configuration .........................................................................91
7.1.3 Factory settings .....................................................................................92
8. Communication with machine control unit............................ 94
8.1 Implementation in the fieldbus system on the
machine control unit ............................................................................94
8.1.1 Implementation in a PROFIBUS network ..........................................94
8.1.1 Implementation in a PROFINET network ..........................................95
8.2 Process image of MQL systems ..........................................................96
8.2.1 Assignment of input bytes (input byte 0 and input byte 1)
- data from MQL system to machine .................................................97
8.2.2 Assignment of input words ............................................................. 100
8.2.3 Assignment of output bytes (output byte 0 and
output byte 1) - data from machine to MQL system ..................... 102

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9. Commissioning/Operation ................................................. 107
9.1 Initial filling ......................................................................................... 107
9.1.1 Depressurizing the aerosol generator ............................................. 107
9.2 Manual filling ......................................................................................108
9.3 Automatic filling ................................................................................. 108
9.4 Commissioning ................................................................................... 109
9.5 Operation ............................................................................................ 110
9.6 Refilling lubricant ............................................................................... 110
10. Cleaning ........................................................................... 111
10.1 Cleaning agents.................................................................................. 111
10.2 Exterior cleaning ................................................................................ 111
10.3 Interior cleaning ................................................................................. 111
10.4 Cleaning the fine filter for compressed air ..................................... 112
10.5 Cleaning the oil filter .......................................................................... 113
11. Maintenance ..................................................................... 114
11.1 General ................................................................................................114
11.2 Refilling lubricant in systems with manual lubricant refill ............ 115
11.3 Draining lubricant .............................................................................. 117
12. Malfunctions, causes, and remedies ................................... 119
12.1 Prior to beginning troubleshooting ................................................ 119
12.2 Malfunctions and their resolution .................................................... 120
12.3 Error with the use of MQL systems with bypass control............... 122
12.4 Error notifications via LED display ................................................... 123
12.5 Replacing defective fuses .................................................................. 125
13. Shutdown, disposal ........................................................... 126
13.1 Temporary shutdown ........................................................................ 126
13.2 Extended shutdown ........................................................................... 126
13.3 Permanent shutdown, disassembly ................................................ 126
13.4 Disposal ............................................................................................... 126
14. Spare parts ...................................................................... 127
15. Accessories ....................................................................... 128

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Explanation of symbols, signs, and abbreviations
Explanation of symbols and signs
General warning Risk of electrical shock Risk of slipping Hot surfaces
Being drawn into machinery Crushing hazard Pressure injection Suspended load
Electrostatic sensitive
components
Potentially explosive
atmosphere Disposal, recycling Disposal of waste electrical and electronic equipment
Wear personal protective gear
(goggles)
Wear personal protective gear
(protective clothing)
Wear personal protective gear
(facial mask)
Wear personal protective gear
(protective footwear)
Unauthorized persons must
be kept away General notes
Warning level Consequence Probability Symbol Meaning
DANGER Death, serious
injury Immediate Chronological instructions
WARNING Serious injury Possible Bullet list items
CAUTION Minor
injury Possible Indicates the requirements that must be met for the actions de-
scribed in the following
IMPORTANT NOTE Property damage Possible

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EN Explanation of symbols, signs, and abbreviations
Abbreviations and conversion factors
re regarding °C degrees Celsius °F degrees Fahrenheit
approx. approximately K Kelvin Oz. ounce
i.e. that is N Newton fl. oz. Fluid ounce
etc. et cetera h hour in. inch
poss. possibly s second psi pound per square inch
incl. including d day sq.in. square inch
min. minimum Nm Newton meter cu. in. cubic inch
max. maximum ml milliliter mph miles per hour
min minute ml /d milliliters per day rpm revolutions per minute
etc. et cetera ccm cubic centimeter gal. Gallon
e.g. for example mm millimeter lb. pound
kW kilowatt l liter hp horsepower
U voltage db (A) sound pressure level kp kilopond
R Resistance > greater than fpsec feet per second
I current intensity < less than Conversion factors
V volt ± plus minus Length 1 mm = 0.03937 in.
Wwatt Ø diameter Area 1 cm² = 0.155 sq.in.
AC alternating current kg kilogram Volume 1 ml = 0.0352 fl.oz.
DC direct current RH relative humidity 1 l = 2.11416 pints (US)
A ampere ≈ approximately Mass 1 kg = 2.205 lbs
Ah ampere hour = equal to 1 g = 0.03527 oz.
Hz Frequency (Hertz) % percent Density 1 kg/cm³ = 8.3454 lb./gal(US)
NC normally closed contact ‰ per mil (thousandth) 1 kg/cm³ = 0.03613 lb./cu.in.
NO normally open contact ≥ greater or equal Force 1 N = 0.10197 kp
≤ less or equal Pressure 1 bar = 14.5 psi
mm2square millimeter Temperature °C = (°F-32) x 5/9
rpm Revolutions per minute Power 1 kW = 1.34109 hp
Acceleration 1 m/s² = 3.28084 ft./s²
Speed 1 m/s = 3.28084 fpsec
1 m/s = 2.23694 mph

1
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1. Safety instructions
1. Safety instructions
1.1 General safety instructions
○The operator must ensure that the in-
structions are read by all persons tasked
with working on the product or who
supervise or instruct such persons. The
operator must also ensure that the staff
fully understands the content of the in-
structions. Putting the products into op-
eration or operating them without having
read the instructions is prohibited.
○Retain the instructions for further use.
○The products described here were
manufactured according to the state of
the art. Risks may, however, arise from
non-compliant usage and may result in
personal injury or damage to material
assets.
○Any malfunctions which may affect safety
must be remedied immediately. In ad-
dition to these instructions, the statu-
tory regulations for accident prevention
and environmental protection must be
observed.
1.2 General behavior when handling the
product
○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.
○Familiarize yourself with the functions
and operation of the product. The speci-
fied assembly and operating steps and
their sequences must be observed.
○Any unclear points regarding proper
condition or correct assembly/operation
must be clarified. Operation is prohibited
until issues have been clarified.
○Unauthorized persons must be kept
away.
○Wear personal protective equipment.
○All safety regulations and in-house
instructions relevant to the particular
activity must be observed.
○Responsibilities for different activities
must be clearly defined and observed.
Uncertainty seriously endangers safety.
○Protective and safety mechanisms must
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 rein-
stalled immediately following conclusion
of work and then inspected for proper
function.
○Any malfunctions that occur must be
resolved according to responsibility. The
supervisor must be notified immediately
in case of malfunctions outside one's in-
dividual scope of responsibility.
○Never use any part of the centralized
lubrication system as a stand or step or
for climbing.

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1.3 Intended use
The minimal quantity lubrication (MQL)
systems of the series UFD10 and UFD20
were designed for internal lubrication of
cutting tools for machining applications.
Internal lubrication refers to the supply of
lubricant by means of the tool spindle and
tools to the friction point between the cut-
ting edge and the workpiece.
Minimal quantity lubrication systems of se-
ries UFD10 and UFD20 are used to feed
lubricants only in compliance with the
specifications, technical data, and limits
presented in this manual.
Usage is permitted exclusively in the context
of commercial or business activity by profes-
sional users.
1.4 Foreseeable misuse
Any usage of the product other than as
specified in this manual is strictly prohibited.
Particularly prohibited are:
○Use outside the specified operating tem-
perature range
○Use of non-specified equipment
○Use without a suitable pressure regulat-
ing valve
○Use in continuous duty
○Use in areas with aggressive, corrosive
substances (e.g., high ozone loads)
○Use in areas with damaging radiation
(e.g., ionizing radiation)
○Use to feed, forward, or store hazardous
substances and mixtures as defined in
Annex I Part 2-5 of the CLP Regulation
(EC 1272/2008) that are marked with
hazard pictograms GHS01-GHS 09
○To feed / forward / 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