SKF 800030 Product manual

Digital grease flow detector
Model 800030
Date of issue July 2016
Form number 400101B
Read manual prior to installation or use of
this product. Keep manual nearby for
future reference.
Installation and maintenance guide

Explanation of safety signals
Indicates hazardous situation which, if not
avoided, could result in minor or moder-
ate injur y.
CAUTION
Indicates hazardous situation which, if not
avoided, may result in death or serious
injury.
WARNING
Indicates hazardous situation which, if not
avoided, will result in death or serious
injury.
DANGER
Safety instruction sign indicates specific
safety-related instructions or procedures.
SAFETY INSTRUCTION
Safety alert symbols identify potential
physical injury hazards. Obey all safety
messages below this symbol to avoid pos-
sible injury or death.
Table of contents
Explanation of safety signals ........ 2
Safety ............................ 3
Introduction ...................... 3
Installation ....................... 4
Detector disassembly. . . . . . . . . . . . . . . 5
Detector re-assembly .............. 6
Service parts/kits .................. 7
Troubleshooting ................... 8
Warranty ......................... 10
Protection of device may be impaired if
used in a manner not specif ied by
manufacturer.
SAFETY INSTRUCTION
2

Safety
Read and observe operating instructions
before installing and operating the flow
detector.
Do not attempt to install, use, or trouble-
shoot prior to fully understanding all safety
and operational instructions.
Application
Model 800030 was designed to generate a
confirmation signal to verify lubrications
events of a critical lubrication point. The unit
would be installed between the lubrication
point of the bearing and the lubricating device
like the injector. Signals are communicated to
SKF LMC 301 or PLC. Detecting both small
0.002 in.3 (32 mm3) and large
0.5 in.3 (8 195 mm3) f low of grease.
!Notice
Follow all local safety regulations
regarding installation, use and
maintenance.
Introduction
Model 800030 a positive displacement flow
detector consisting of oval gears. One gear has
a built-in diametric magnet. As the magnet
turns with the gear, a rotating motion of
magnetic flux results.
As the magnet rotates, a hall sensor detects
the magnet flux motion. This motion is
processed by an encoder creating and sending
a digital signal to an outside controller.
A blinking LED indicates processed signals.
Specifications
Media Grease grade 0 to 2
Grease ports 1/8 in. NPT F
Wetted parts Aluminum, steel, nitrile, rubber and nylon
Maximum pressure 3,000 psi (206 bar)
Maximum operation temperature 140 °F (60 °C)
Minimum operation temperature –30 °F (–34 °C)
Sensitivity1) 0 – 140 °F –17 – 60 °C ) 0.002 – 0.5 in3(32 – 8 195 mm3) per signal generated
–30 – 0 °F (–34 – 17 °C ) 0.005 – 0.5 in3(81,9 – 8 193 mm3) per signal
Maximum altitude 10,000 ft. *3 048 m)
Maxiumum humidity 100%
Dimensions 2 x 1.6 x 1.9 in. (51 x 42 x 48 mm)
Protection IP67
Weight 0.35 lbs. (0.159 kg)
Supply voltage 12 to 30 V DC
Polarity protection 12 to 30 V DC
Nominal supply current 5 mA
Maximum supply current 35 mA
Output signal 12 to 30 V DC
Maximum output signal 30 mA
1) Entrapped air may compromise minimum sensi t ivi t y level.
3

!Notice
Connector cable must be ordered
separately.
Refer to service parts list, page 7 for
more information.
!Notice
Detector requires a controller that
accepts digital signal via a connector
assembly par t no. 280137.
Installation
Installation guidelines
• Units are non-directional.
• Use thread sealant on all pipe threads.
• Do not overtighten line connections.
• Perform system tests, checking for proper
functioning and connection sealing.
Installation procedure
1 Shut off all grease flow through grease
line.
2 Attach inlet and outlet connections to flow
detector.
3 Attach one end of connector cable to flow
detector.
4 Attach remaining end of connector cable
to controller.
5 Test detector by opening grease line to
supply grease flow to detector.
6 Verify LED is blinking, indicating that the
flow detector is working properly.
!Notice
Electronic controller module is non-
repairable. Replace detector if electronic
controller module is found to be damaged
or faulty.
Do not disassemble detector with fluid
supplied to detector or line pressurized.
Remove pressure and supply before
disassembly.
Failure to comply may result in death or
serious injury.
WARNING
!Notice
Grease flow detector is to be in-
stalled in-line with grease line so that
flow of lubricant is directed through
sensor.
Assembly has an IP67 environmental
rating and does not require additional
enclosures.
Sensor is approved for indoor/outdoor
use.
4

V DC (brown)
+ V DC
Signal (black)
Ground (blue)
Ground blue
+V DC
PLC or
controller
Digital
Input
DC power
source
Flow sensor cable
Ground
F ig . 3
F ig . 2
1.4
2.3
2.1
2.4
1.2 1.3
1.1
Detector disassembly
1 Remove head bolts (2.4) and washers (2.3)
from cover (2.1) († fig. 3).
2 Remove the detector cover (2.1) and
o-ring (1.4).
3 Remove oval gears (1.2, 1.3).
4 Clean and inspect all parts. Replace any
suspect, worn or damaged components.
Wire pin connections
1Ground
2Output signal
3Positive V DC
1
2
3
F ig . 1
5

!Notice
Check gear rotation by turning
either gear.
If gears are not in mesh correctly or do
not rotate freely, remove one gear and re-
place correctly at 90° to other gear
(† fig. 4). !Notice
If gears do not turn or LED is not
blinking, perform assembly steps again.
Detector assembly
1 Align rib on top of cover (2.1) with “magnet”
on body (1.1) († fig. 4).
2 Insert both gears at 90° angles to each
other († fig. 4).
3 Lightly grease the o-ring (1.4) and place it in
the detector body (1.1).
F ig . 4
90°
1.4
2.1
7
1.1
1.3
1.2
4 Place cover (2.1) on detector body (1.1),
taking care not to damage o-ring (1.4).
5 Install washers and bolts (2.3, 2.4),
tightening bolts in a diagonal pattern to
0.73 ft.lbf (1 Nm).
6 Visually check that the cover assembly (2.1)
has been pulled down evenly († fig. 4).
Testing procedure
1 Apply 12 to 30 V DC to pin 1 and 3 of con-
nector († fig. 1 page 5).
2 Apply low air pressure or pressurized
grease ( by grease gun, for example) to any
port of the detector.
3 As a result of this action, the gears should
turn, and LED should begin blinking.
6

1.1 1.3
1.2
1.4
2.3, 1.5
2.4, 1.6
2.1
3, 4, 5, 6
2.1
2.2
F ig . IP B 1
Service parts/kits
Item no. Pat no. Description Qty
1280135 Body assembly kit 1
1.1 Body assembly 1
1.2 Oval gear
1
1.3 Gear with magnet 1
1.4 Square o-ring 4
1.5 Washer
1.6 8-32 x .75 THD-Lock.SHC screw 4
2280136 Cover assembly kit
2.1 Cover assembly
1
2.2 Square o-ring 4
2.3 Washer 4
2.4 8-32 x .75 THD-Lock.SHC screw
31) 280137-03 Cable assembly 9.8 ft . (3 m) 1
41) 280137-15 Cable assembly 49.2 ft . (15 m) 1
51) 280137-30 Cable assembly 98.4 ft . (30 m) 1
61) 280137-45 Cable assembly 147.6 ft . (45 m) 1
1) Must be ordered separ ately.
7

Troubleshooting*
Problem Possible cause Remedy
Detector never registers grease
output.
No signal from magnet. Check magnets and gear if required.
Damaged controller/PCB. Replace detector.
No grease passed through detector even
lubrication cycle occurred without delivering grease
to detector’s inlet.
The system detected a failure correctly
and lubrication device like the injector or
grease line needs to be checked.
Media flow is below minimum required flow rate. Increase input.
Dirt particles jamming the rotors. Remove rotors and remove any dirt and
contamination.
Low viscosity of media. Use grease grade 0 to 2.
Air in the system. Purge air from system.
The detector is not registering
grease output every lubrication cycle.
(Detector miss signal.)
Bad contact between connector and outlet wire
connector.
Replace wire connector.
Low input of media. Increase input.
Grease leakage. Screw loose or missing. Tighten screws.
Damaged o-ring. Replace o-ring.
The detector pressurized over maximum
pressure rating.
Replace the detector and reduce inlet
pressure.
*Indicates change.
8

Declaration of conformity
Declaration of conformity according the EMC
directive 2014/30/EU.
We declare that the model of the Digital grease
flow detector in the version supply by us, com-
plies with the provisions of the above men-
tioned directive.
Applied harmonized standard in particular:
EN61326-1 Electrical equipment for meas-
urement, control and laboratory use. EMC requirements-
Part 1: General requirements (IEC 61326-1)
Declaration of conformity according to direc-
tive 2014/35/EU relating to low voltage.
Safety evaluation.
We declare that the model of the Digital grease
flow detector in the version supplied by us,
complies with the provisions of the above
mentioned directive.
Applied harmonized standards in particular:
EN61010-1 Safety requirements for electri-
cal equipment for measurement, control and
laboratory use -Part 1:
General requirements (IEC 61010-1).
Robert Hoefler
Director Product Development and Product Engineering
St. Louis, MO
Made in USA
5148 N. Hanley Road
St. Louis, MO 63134
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®SKF is a registered trademark of the SKF Group.
® Lincoln is a registered trademark of Lincoln Industrial Corp.
©SKF Group 2016
The contents of this publication are the copyright of the publisher
and may not be reproduced (even extracts) unless prior written
permission is granted. Every care has been taken to ensure the
accuracy of the information contained in this publication but no
liability can be accepted for any loss or damage whether direct,
indirect or consequential arising out of the use of the information
contained herein.
PUB LS/I4 15881/1 EN.R2 · July 2016 For m 40 010 1B
Warranty
The instructions do not contain any information on the
warranty. This can be found in the General Conditions of
Sales, which are available at: www.skf.com/lubrication.