SKF AM1000 User manual

Aerosol Monitor Minimum Quantity
AM1000 Lubrication Systems
Operating Manual
Version 1

Imprint
The Operating Manual is a part of the scope of delivery of a SKF aerosol
monitor AM1000.
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
changes to adapt to technical improvements. Reprinting or copying
these Operating Instructions as a whole or in parts is only permitted with
the agreement of SKF LUBRICATION SYSTEMS GERMANY AG.
Editor
Dipl.-Ing. J. Schwartz

Kapitel 0 - Contents Seite 1
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Contents
Contents.................................................................................................... 1
1Information Concerning the EC Declaration of Conformity
and the Manufacturer´s Declaration ................................................... 2
2Notes to the Instructions ..................................................................... 3
3Field of Application ............................................................................. 4
4Safety Instructions .............................................................................. 4
4.1 Using the Aerosol Monitor ..............................................................4
4.2 Personnel ........................................................................................5
4.3 Working on the Aerosol Monitor ....................................................5
5Transport, Delivery, Storage............................................................... 6
6Design and Function........................................................................... 6
6.1 System Design ................................................................................6
6.2 Method of Operation.......................................................................7
6.3 Operation Modes ............................................................................7
6.3.1 Autonomous Operation with Teach Function ........................ 7
6.3.2 Operation with Connection to the Bus System of a
SKF LUBRILEAN®Digital Super MQL System....................... 7
6.4 Functions.........................................................................................7
6.4.1 Laser longlife function ............................................................. 7
7Installation........................................................................................... 8
7.1 Configuration...................................................................................9
7.2 Installation .....................................................................................10
7.3 Connecting the Aerosol Lines ......................................................11
7.4 Electrical Connection....................................................................12
7.4.1 Supply Voltage and Analog Current Signal ......................... 12
7.4.2 Bus Connection / Teach Adapter ......................................... 12
8Operation...........................................................................................14
8.1 Autonomous Operation ................................................................14
8.2 Operation with Connection to the Bus System of a
SKF LUBRILEAN®Digital Super MQL System................................15
9Maintenance......................................................................................16
10 Failures..............................................................................................16
11 Decommissioning ..............................................................................18
12 Service ..............................................................................................18
13 Technical data ...................................................................................19

Kapitel 1 - Information Concerning the EC Declaration of Conformity and the Manufacturer´s Declaration Seite 2
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For the product designated below:
Aerosol Monitor
AM1000
we herewith certify that it complies with 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 listed in the documents that come with the
product are to be observed.
(c) Putting the certified products into operation is only allowed after it
has been ensured that the machine, the vehicle or any other unit in
which the product has been installed complies with the regulations
and requirements of the applicable directives.
(d) Operating the products on a non-standard mains voltage, or ignoring
installation instructions can have an effect on the EMC properties
and/or the electrical safety.
We further declare that the above-mentioned product:
has been designed for installation in a machine / for assembly with
other machines into a machine in accordance with the EC machinery
directive 98/37/EC, Annex II B. Commissioning is not admissible until
evidence has been provided that the machine in which this part is
installed or to which this part is connected, complies with the
regulations set forth in the EC directive 98/37/EC.
with reference to the EC directive 97/23/EC concerning apparatus
subjected to pressure this product must only be used as intended
and in accordance with the notes in the documentation. The following
must therefore be observed in particular:
SKF products are not suited for use in connection with fluids of group I
(hazardous fluids), definition in accordance with article 2 paragraph 2
of the Directive 67/548/EEC dtd. 27th June, 1967; and are not
approved for application with such.
SKF products are not designed and not approved for any utilization in
conjunction with gases, liquified gases, gases dissolved under
pressure, vapours, and liquids whose vapour pressure at the
maximum permissible temperature is more than 0.5 bars above the
normal atmospheric pressure (1013 mbars).
1 Information Concerning the EC Declaration of Conformity and the Manufacturer´s
Declaration

Kapitel 2 - Notes to the Instructions Seite 3
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When used as intended, the products supplied by us do not reach the
limit values listed in the article 3 paragraph 1, sections 1.1 to 1.3 and
paragraph 2 of the directive 97/23/EC. They are thus not subject to the
requirements of Appendix I of the Directive. Consequently, they do not
obtain a CE mark with respect to the Directive 97/23/EG. They are
classified by us to come under article 3 paragraph 3 of the directive.
SKF products must only be employed in accordance with their
intended use. Using the products or putting them into operation in a
hazardous area according to ATEX Directive 94/9/EG with a gas
atmosphere or a dust atmosphere is not permitted.
If required, you may request the declaration of conformity or
manufacturer´s declaration for this product from our central contact
address.
2 Notes to the Instructions
The aerosol monitor has been built according to the generally
recognized technical standards. It complies with the valid occupational
safety and accident prevention regulations. Still hazards may be involved
in their 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 hazard, we kindly ask you to read the present
manual carefully and observe the notes contained in it.
Use the table of contents to locate the desired information promptly and
successfully.
Please take note of the symbol shown below. It calls attention to special
situations:
Texts marked by this icon point out specific hazards or
identify work that has to be carried out with particular care.
These instructions are a part of the unit. They must be handed over to
the new user when the unit is sold.

Kapitel 3 - Field of Application Seite 4
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3 Field of Application
All products from SKF LUBRICATION SYSTEMS GERMANY
AG may only be used as intended and only according to the
specifications in the Operating Instructions that belong to the
units.
We particularly want to point out that any hazardous materials
- in particular substances that are classified as dangerous
according to EG RL 67/548/EWG Article 2, Paragraph 2 - may
only be filled in SKF products and conveyed and/or
distributed with these products after written authorization
from SKF LUBRICATION SYSTEMS GERMANY AG has been
obtained.
No SKF product is approved for being used in conjunction
with hot gases, liquified gases, gases dissolved under
pressure, vapours and liquids whose vapour pressure at the
maximum permissible temperature is more than 0.5 bars
above the normal atmospheric pressure (1013 mbars).
Apart from the particularly identified products, no product
produced by SKF is approved for utilization in hazardous
areas.
The aerosol monitor is a measuring sensor used for continuously
monitoring the aerosol flow of minimum quantity lubrication systems
(MQL systems). Although it has specifically been developed for
utilization in conjunction with the SKF LUBRILEAN®Digital Super MQL
system, it may as well be used independently of this system.
Other use or use beyond this purpose is considered unintended. SKF
will not accept liability for damages resulting from such unintended use.
4 Safety Instructions
Please observe the following safety instructions in order to ensure a
troublefree functioning of the aerosol monitor and to avoid damages.
4.1 Using the Aerosol Monitor
The aerosol monitor may only be used as intended, when it is in a
technically faultless state, in a safety- and hazard-conscious way and
when the Operating Instructions are observed. Especially errors that
could affect safety must be resolved without delay. Contact a SKF
service centre (see Chapter 12, page 18) for this purpose.
The aerosol monitor is intended to be used in conjunction with a
minimum quantity lubrication system (MQL system). All safety
instructions listed in the Operating Instructions of the MQL system must
therefore be observed when the aerosol monitor is used within the MQL
system.
The aerosol monitor employs a class-1 laser which does not represent
any risk when the unit is used as intended. However, do not look into the
laser beam, and do not insert strongly reflecting objects into the aerosol
channel.
Unauthorized modification of the aerosol monitor and using unapproved
spare parts and auxiliaries are not permitted, and would lead to losing
the warranty.
Units that can no longer be used must be made unusable and disposed
of properly.

Kapitel 4 - Safety Instructions Seite 5
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4.2 Personnel
The installation, electrical connection and all interventions such as
repairs, component replacement, etc. may be carried out only by
adequately qualified and instructed personnel.
There can be significant damage and injuries when the
aerosol monitor is connected improperly.
Qualified personnel has been trained, instructed and specifically ordered
by the owner to perform the work. Due to their training, experience and
instruction, these persons are familiar with the applicable standards,
regulations accident prevention regulations, and operating conditions.
They are authorized to carry out the necessary activities, and are able to
recognize and avoid possible hazards. The definition for qualified
personnel and the prohibition of the employment of non-qualified
personnel are stipulated by DIN VDE 0105 or IEC 364.
4.3 Working on the Aerosol Monitor
The aerosol monitor is installed in the aerosol line of an MQL system.
Any work that is carried out during the installation on the aerosol
monitor, for example, thus requires the safety instructions in the
Operating Instructions of the MQL system to be observed.
CAUTION DANGER OF LIFE
Prior to starting any installation, service or repair work, the
corresponding experts must disconnect the power to the
system. Working on MQL systems that are not de-energized
may lead to personal injuries.
Prior to starting any installation, service or repair work, the
MQL system must be separated from the compressed air
supply. Working on systems under pressure could lead to
personal injuries.

Kapitel 5 - Transport, Delivery, Storage Seite 6
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5 Transport, Delivery, Storage
The aerosol monitor is packed in commercial standard packing
according to the requirement of the destination country and of DIN ISO
9001.
There are no limitations for road, air or sea transport.
Upon receiving the package, please check the items for possible
damage, and ensure the package is complete by checking the supply
papers. Keep the packaging material until any and all problems have
been clarified.
Generally, units should be stored in dry and dust-free environment. The
storage temperatures can be found in the specifications.
6 Design and Function
6.1 System Design
Fig. 1. Design of the aerosol monitor
1. Connections for aerosol lines
2. Connection for supply voltage and analog signal
3. Connection for bus link or teach adapter
4. LED indicator for operating voltage
5. LED indicator for signals
6. LED indicator for bus communication
7. Bottom lid (access to DIP switches)
8. Boreholes for fixture

Kapitel 6 - Design and Function Seite 7
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6.2 Method of Operation
The aerosol monitor is a scattered-light monitor that is installed in the
aerosol line between aerosol generator and lubrication point of an MQL
system. There it measures the density of the aerosol produced by the
MQL system.
In the SKF terminology, the term aerosol in minimum quantity lubrication
technique stands for air mixed with finest lubricant droplets. The aerosol
density is the quantity of the oil contained in the aerosol, related to the
air flow.
The aerosol monitor supplies a measured analog signal that can be
employed for controlling the aerosol production. If the oil content in the
aerosol drops at a constant air flow, the aerosol density and,
consequently, the measured signal drop, too. The measured signal
remains constant if air stream and aerosol-oil throughput change
equally. Thus, the measured signal represents the concentration of the
oil in the air that flows along the monitor, not for the absolute oil quantity
contained in the air stream.
6.3 Operation Modes
6.3.1 Autonomous Operation with Teach Function
The aerosol monitor can also be used in stand-alone mode, i.e. without a
connection to a SKF LUBRILEAN®Digital Super MQL system. To be able
to use the full range of the measured signal in this case, you can define a
measurement range whose highest and/or lowest value correspond to
the highest and the lowest value, respectively, of the measured signal
(teaching).
6.3.2 Operation with Connection to the Bus System of a SKF
LUBRILEAN®Digital Super MQL System
The aerosol monitor features a bus interface via which the monitor can
be connected to the bus system of a SKF LUBRILEAN®Digital Super MQL
system. This provides the MQL system with information, such as the
aerosol-oil volume flow, that permit the aerosol generation to be
optimized.
6.4 Functions
6.4.1 Laser longlife function
The laser is switched off automatically when the aerosol monitor detects
that aerosol does not flow through the measuring chamber and the
signal approaches zero. Next, the aerosol monitor checks at 10-second
intervals whether there is aerosol in the line. The laser is switched back
on as soon as aerosol flows through the measuring chamber.
Note:
This function is particularly suitable for slow processes to which a signal
delay of up to 10 seconds is not relevant.

Kapitel 7 - Installation Seite 8
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7 Installation
Use the following flow chart to carry out installation and commissioning
of the aerosol monitor:
Configuration
Erection
Connecting the aerosol lines
Electrical connection and settings
Installation work may only be carried out on the previously
de-energized and de-pressurized MQL system.
The aerosol monitor may only be installed and connected by
properly qualified and instructed personnel. The safety
instructions in the Operating Instructions of the aerosol
monitor and the MQL system are to be observed.