SKF AS-1Q-1T05KA4+140 User manual

EN
Motor-driven pump AS
Operating manual
AS

EN
Page 1
951-130-400, edition 04/2009
Imprint
The operating manual is part of the scope of
the SKF's motor-driven pump unit AS for dual-
line centralized lubrication systems.
The manual has been edited in conformity with
applicable standards and rules for technical
documentation.
© Copyright
SKF 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.
Imprint

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951-130-400, edition 04/2009
Contents
Contents
Imprint ............................................................. 1
Contents .......................................................... 2
Introduction .................................................... 3
Notes on the operating manual ................... 3
Safety instructions ......................................... 4
Applications .................................................... 5
Lubricants ....................................................... 5
Version ............................................................ 6
Design ............................................................. 8
Function ........................................................ 10
Installation .................................................... 10
Outlet connection ......................................... 10
Half-cycle indicator ...................................... 11
Level monitoring .......................................... 12
Minimal level ............................................ 12
Minimal and maximal level .................... 12
Adjustment of the ow rate ........................ 13
Commissioning ............................................. 14
Bleeding ........................................................ 14
Bleeding the pump .................................. 14
Bleeding the circuit .................................. 14
Reservoir lling ............................................ 14
Maintenance ................................................. 15
Faults ............................................................. 16
Placing out of service .................................. 17
Temporary standstill ................................ 17
Final standstill ......................................... 17
Spare parts ................................................... 17
Technical data ............................................... 18
Service .......................................................... 19

EN
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951-130-400, edition 04/2009
Introduction
Introduction
The motor-driven pump units AS are remark-
able in their operational reliability and long
service lives. The lubrication systems are made
in conformity with the generally recognized
rules of technology and the applicable safe
working practices and the rules for accident
prevention. Still hazards may be involved in
their use, which can lead to injury of operators
or other persons or damage the machine or
other property.
To ensure trouble-free operation and prevent
hazard, we kindly ask you to read the pres-
ent manual carefully and observe the notes
contained in it.
The present manual gives the instructions
for operating and servicing standard motor-
driven pump units AS († page 6). In the case
of a special pump unit AS, read carefully the
technical sheet delivered with the pump with
all specic technical data (motor, level switch,
etc...).
Notes on the operating
manual
Text marked with this sign alerts to
special hazards or work that must be
performed with caution.
Keep the operating manual in a safe place so
that it is always available wherever the unit is
in use.
This operating manual is part of the unit, and
it must be given to the operating company
upon sale of the unit.

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951-130-400, edition 04/2009
Safety instructions
Safety instructions
Please comply with the following safety
instructions in order to prevent possible
damage and to ensure that the motor-driven
pump units AS work properly.
Use the motor-driven pump units only in
technically perfect condition for their intended
use. Be aware of hazards and observe the
operating manual.
Especially errors that could affect safety must
be resolved without delay. Safety measures
corresponding to the parameters of the lubri-
cant supplied must be stipulated.
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 of by SKF.
The electrical connection and all interventions
such as repairs, component replacement, etc.
may be carried out only by properly qualied
and instructed personnel.
If units are improperly connected,
substantial material or personal
damage my be the consequence.
Repair work must only be performed after a
trained specialist has disconnected the unit
from power.
Working on systems under electrical
voltage could lead to personal injury.
The dual-line centralized lubrication system
connected to the motor-driven pump unit may
be under pressure. Before extension work,
changes, repairs, etc. it must be depressurized.
Working on systems under pressure
could lead to personal injury.
Unauthorized modications to the
motor-driven pump unit and the
use of unauthorized spare parts and
aids are prohibited and disqualify the
warranty.
Worn-out motor-driven pump units must be
made inoperable and disposed of properly.

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Applications
Applications
All products from SKF may be used
only for their intended purpose
as described in this brochure and in
any instructions. If operating instructions
are supplied with the products, they must
be read and followed.
Not all lubricants are suitable for use in
centralized lubrication systems. SKF does
offer an inspection service to test customer
supplied lubricant to determine if it can be
used in a centralized system. SKF lubrica-
tion systems or their components are not
approved for use with gases, liqueed
gases, pressurized gases in solution and
uids with a vapor pressure exceeding
normal atmospheric pressure (1013 mbars)
by more than 0,5 bar at their maximum
permissible temperature.
Hazardous materials of any kind, especially
the materials classied as hazardous by
European Community Directive EC 67/548/
EEC, Article 2, Par. 2, may only be used to
ll SKF centralized lubrication systems and
components and delivered and/or distrib-
uted with the same after consulting with
and receiving written approval from SKF.
The motor-driven pump units AS serve to
supply lubricant to centralized lubrication
systems. Other use or use beyond this purpose
is considered unintended. SKF will not accept
liability for damages resulting from such unin-
tended use.
Only authorized lubricants for the
pump type may be supplied. Unsuit-
able lubricants could lead to the
pump failing and possibly severe properly
damage and personal injury.
Lubricants
The motor-driven pump unit AS can supply
lubricants with the following NLGI grade:
greases up to NLGI grade 2•
A list of authorized lubricants can be found on
the Internet at www.skf.com/lubrication. The
lubricants recommended correspond in their
composition to customary safety regulations,
and they are suitable for use in centralized
lubrication systems.
Whenever using other lubricants, keep in
mind that there are lubricants which, although
within the authorized limits, nevertheless are
unsuitable for dual-line centralized lubrication
systems because of their characteristics.
Keep in mind that lubricants are environ-
mentally unfriendly substances and that their
transport, storage and processing require that
special safety measures be taken.

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Version
Table 1 lists the standard versions of the
motor-dtiven pump unit AS.
If a motor-driven pump unit is not
listed in table 1, please refer to the
delivered technical sheet to know the
specic technical data of the unit.
Table 1 Standard motor-driven pump units AS
Order No. Half-cycle
indicator
Reservoir
capacity Level monitoring
AS-1Q-1T05KA4+140 visual 5 min.
AS-1Q-1T05KB4+140 visual 5 min. + max.
AS-1Q-1R15KA4+140 visual 15 min.
AS-1Q-1R15KB4+140 visual 15 min. + max.
AS-1Q-1R30KA4+140 visual 30 min.
AS-1Q-1R30KB4+140 visual 30 min. + max.
AS-1Q-3T05KA4+140 electric 5 min.
AS-1Q-3T05KB4+140 electric 5 min. + max.
AS-1Q-3R15KA4+140 electric 15 min.
AS-1Q-3R15KB4+140 electric 15 min. + max.
AS-1Q-3R30KA4+140 electric 30 min.
AS-1Q-3R30KB4+140 electric 30 min. + max.
Version

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1345789011126
Fig. 1 Pump AS-1Q-3R15KA4+140
motor1.
manometer2.
reservoir (15 kg)3.
level switch4.
level indicating rod5.
max. level mark6.
outlet ports7.
half-cycle indicator8.
pressure regulator9.
lling10.
lter11.
Design

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951-130-400, edition 04/2009
Design
Figure 1 shows the essential design of the
motor-driven pump unit AS.
The lubricant reservoir is located on the pump
housing. It is equipped with a follower plate in
order to prevent any dust or air penetration
and cavitation. According to the model it has
different level controls (min. level, min. and
max. level). The user rells the reservoir with
the ller coupling on the back side of the pump
housing. This coupling has a lter to ensure the
cleanliness of the lubricant.
The high resistance wheel and worm couple
permit to have a ration of 1/40. The pump
cannot discharge until the drive shaft has car-
ried out a number of revolutions at least equal
to the reduction.
A standard changeover block (†g. 2) is
mounted on the pump housing. It is relatively
compact but it is the core of the AS unit. The
standard changeover block consists of a pump,
changeover valve, lter element and pressure
control valve.
The pump is a double-action piston pump
with one piston and 2 automatically actuated
valves. The changeover valve (1) is activated by
overpressure. It has 2 pilot pistons serving the
main piston, thus avoiding a dead point. The
delivery lter (2) is protecting the system. It is
located on the circuit before the changeover
unit. This ne lter is very easy to remove and
clean up. The pressure regulator (3) makes it
possible to set the pressure in the two lines. In
order to ensure the security of the system, the
pressure regulator can be sealed in order to
avoid any accidental modication.
It is possible to control the good operation of
the changeover unit by means of two differ-
ent control devices: a sight indicator (indicat-
ing rod) of half-cycle or an electric indicator
(switch with LED) of half-cycle .
Fig. 2 Changeover block
132Design

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15741003865
525525594
345345320
Fig. 3 Dimensions of the AS pumps
AS pump, 30 kg reservoir AS pump, 15 kg reservoir AS pump, 5 kg reservoir
Design

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951-130-400, edition 04/2009
Function
Function
When the motor-driven unit is switched on,
the primary shaft is driving via a reduction
gear (1/40) a catch, which is actuating a piston
pump.
The double effect piston pump is deliver-
ing lubricant into the changeover block.
The changeover block is normally delivering
alternatively lubricant to two main lines. The
changeover valve is rst delivering lubricant to
the rst main line as the second main line is
relieving (lubricant is returning to the res-
ervoir). The pressure is building up into the
rst line until reaching a preset changeover
pressure. The pressure can be monitored at
any time with a manometer. When the preset
pressure is reached, the changeover valve is
switching from the rst main line to the second
main line. Then the AS unit is delivering lubri-
cant to the second main line, as the rst one
is relieving. The half-cycle indicator is showing
the changeover process between the two lines.
Half-cycles are carried out the one after the
other until the AS unit is switched off. When
the unit will be switched on again, it will
restart its operation exactly where it has been
stopped.
Installation
The motor-driven pump AS has to be installed
on a horizontal surface with the reservoir
pointing vertically upward. Maintain safe dis-
tance above and all around the unit.
When drilling installation holes
always pay attention to any supply
lines or other units as well as further
sources of dangers such as moving parts.
170
170
4 × Ø11
The supply voltage on site must
agree with the information on the
nameplate. Check the fusing of the
circuit. Use only the original fuse with the
required ampere value. If other fuses are
used, damage to property of personal injury
may be the consequence.
Fig. 4 Drilling template for motor-driven
pump AS
Outlet connection
The changeover block of the motor-driven
pump unit has two outlets dispensing lubricant
to the two main lines. Tubes of diameter 8×10
can be connected to these outlets.
Fig. 5 Outlet connection on changeover block
G 3/8 A
double
tapered
sleeve
410-001
connector
RM010
tube 8×10

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Half-cycle indicator
The motor-driven pump unit can have two
different devices to indicate the good function
of the half-cycle changeover.
This can be a mechanical device. A rod on the
side of the changeover block is indicating when
the changeover has been carried out. The indi-
cating rod is out when the rst half-cycle is in
operation and it is drawing in when the second
half-cycle is starting.
This can also be an electric device. An electric
sensor is sending a signal to a control unit
every time the half-cycles are switching and
a LED on the sensor is also signaling every
changeover. This sensor makes it possible to
monitor at distance the good function of the
motor-driven pump AS.
PNP
BN/1BU/3BK/2 (NC)BK/4 (NO)(-)(+)
Fig. 6 Wiring diagram of the half-cycle indicator
Half-cycle indicator

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Max. level
Min. level
13
12
11
14
Max. level
Min. level
13
12
11
14
Fig. 8 Pulse diagram of the min. level monitoring
Fig. 9 Pulse diagram of the min. and max. level monitoring
Level monitoring
Level monitoring
The motor-driven pump AS can have a level
switch with two different function mode
according to the unit model. In both cases it is
a NO + NC level switch.
Minimal level
The level contact switches when the minimal
lubricant level has been reached and switches
back when the user starts to rell the reser-
voir.
Minimal and maximal level
The level contact switches when the minimal
lubricant level has been reached and switches
back when the maximal level has been
reached.
14121311
Fig. 7 Wiring diagram of the level switch

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951-130-400, edition 04/2009
Adjustment of the ow rate
The motor-driven pump AS might have a ow
regulator directly tted to the pump block.
According to the model the regulator has one
or two adjusting screw(s).
Remove the protective cap from the adjust-•
ing screw.
Screw in the increase the ow rate.•
Screw off to reduce the ow rate.• 1234Adjusting screw1.
Position ball2.
Groove – max. ow rate3.
Groove – min. ow rate4.
Fig. 10 Flow rate adjusting screw
Number of screw turnsFlow ratecm³/min
1500 rpm
3000 rpm
Flow ratecm³/min
mpr 0051
0003
Screw stopNumber of screw turns 1Number of screw turns 2012345789621456307060504030201075 cm³ min37,5 cm³ min
mpr
0123457869107060504030201075 cm³ min37,5 cm³ min
75 cm3/min 75 cm3/min
37,5 cm3/min 37,5 cm3/min
Fig. 12 Flow rate, regulator with two adjusting
screws
Fig. 11 Flow rate, regulator with one
adjusting screw
Flow rate adjustment

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951-130-400, edition 04/2009
Reservoir lling
Only authorized lubricants for the
pump type may be supplied. Unsuit-
able lubricants could lead to the
pump failing and possibly severe properly
damage and personal injury.
Filing with lubricant has to be done with the
grease nipple on the side of the pump housing.
Remove the protective cap and connect•
the lling pump to the grease nipple (ller
coupling G 1/2).
Fill the reservoir with lubricant free
of air bubbles.
Fill the pump until the red marks on the•
indicating rod of the reservoir appear.
Disconnect the lling pump and put back •
the protective cap. Bleed the pump unit
and the dual line lubrication system. It is
also possible to bleed the steel reservoir.
Therefore press the button on the top of the
indicating rod.
Commissioning
Before starting the motor-driven
pump unit check if all connections
have been well mounted and tight-
ened.
Respect the rotation direction of the
motor, which is indicated by an arrow
on the pump housing.
To ensure the good function of the dual line
lubrication system, it is recommended to prell
the different lubrication line before to connect
them to the motor-driven pump unit.
Bleeding
Bleeding the pump
Fill the reservoir•
Loosen the plug from the lter element•
Operate the motor-driven pump unit until•
clean and bubble-free lubricant is coming out
Tighten the plug from the lter element•
Bleeding the circuit
Open the ends of the main lines•
Operate the pump unit until lubricant is•
coming regularly out at the ends of the rst
main line.
Close the ends of the rst main line.•
Continue to operate the pump unit until•
lubricant is coming regularly out at the ends
of the second main line.
Close the ends of the second main line.•
Operate the pump unit until lubricant is•
coming out at every lubrication point, meter-
ing unit being set at their maximum delivery
rate.
Commissioning

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951-130-400, edition 04/2009
Maintenance
Maintenance work may be carried
out only by qualied and trained
specialists instructed to do so.
Maintenance work may be carried
out only after a trained specialist has
disconnected the unit from power.
Working on systems under electrical voltage
could lead to personal injury.
The lubrication system may be under
pressure. Before extension work,
changes, repairs, etc. it must be
depressurized.
SKF motor-driven pumps AS are for the most
part maintenance free. To ensure they work
properly, however, please regularly check the
following:
Regularly check the level of lubricant in the•
reservoir and, if necessary, replace rell the
reservoir.
Check the pump regularly for external dam-•
ages and leaks.
All electrical connections and lines must be•
checked regularly for damage and to ensure
that they are rmly in place.
It is important to clean regularly the lter •
element of the changeover block.
Any faults found must be properly rectied •
before the system is activated again.
Maintenance

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Faults
All interventions such as repairs,
component replacement, etc. may be
carried out only by properly qualied
and instructed personnel.
Repair work may be carried out only
after a trained specialist has discon-
nected the unit from power. Working
on systems under electrical voltage could
lead to personal injury.
The lubrication system may be under
pressure. Before extension work,
changes, repairs, etc. it must be
depressurized.
Table 2 contains an overview of problems,
which you can remedy yourself. You should
contact the SKF if the problem can not be
rectied by taking measures described here.
Table 2 Fault analysis and remedy
Problem Possible cause Remedy
Pump pressure and/or
delivery rate to low
Air in the pump housing
or in the reservoir
Fill the reservoir and bleed
Grease lter clogged Clean the lter
Unsuitable lubricant Empty the entire centralized lubrication system of
unsuitable lubricant
and ll it with new lubricant.
The old lubricant must be properly disposed of.
Pump does not deliver Pump not bled Bleed the pump
Power supply interrupted Turn on power
Motor defective Replace the motor
Reservoir empty Fill the reservoir
No lubricant at the lines
ends
Leaks on lines Check the lines. Replace any defective lines or con-
nectors if necessary
Lines or lubrication points
clogged.
Check the lines. Replace any defective lines or con-
nectors if necessary
Lubricant overowing
from reservoir without
being full
Lubricant passing over
the follower plate
Remove the cover and take away the lubricant
above the follower plate. Remove the follower plate
and check the gasket.
Faults

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Placing out of service
Temporary standstill
Comply with the instructions from the chapter
Transport and Storageif the motor-driven
pump unit AS is to be at a standstill for a
longer period of time.
Final standstill
If you want to bring the motor-driven pump
unit to a permanent standstill, please comply
with the legal stipulations for disposal of
grease containing components.
The system can also be taken back by SKF for
disposal if the costs are covered.
Spare parts*
Order No. Designation
GM130AC315 Manometer 0 to 315 bars
UL10.17 Motor 230/400 V AC - 50 Hz, 0,75 KW, shape B14, ange FT115
GM215 Level switch
AC.3507 Electric half-cycle indicator
MS100A-RE Changeover block + accessories (seals and screws)
*) Non-exhaustive listFor further information about the spare parts
of the motor-driven pump unit AS, please
contact the SKF Service center.
Placing out of service

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Technical data
Technical data
Pump
Flow rate ................................................................................. 65 cm3/min
1,9 cm3/ stroke
Pressure max. .............................................................................. 175 bar
Changeover pressure, adjustable and with seal secured .................................................... 50 to 175 barsFactory setting ............................................................................ 100 barFilter ................................................................................................ 0,8 mm
Operating temperature ..................................................... –25 to +50 °C
Lubricant (grease) .................................................. up to NLGI grade ≤2
Filler coupling .......................................................................... G 1/2 male
Outlet .................................................................................................. G 3/8
Motor (CE marking)
– Voltage .............................................................230/400 V AC – 50 Hz
– Power ...................................................................................... 0,75 kW
– Speed ............................................................................... 1 500 min–1
– Protection .................................................................................... IP 55
– Insulation class ................................................................................... F
Half-cycle indicator
Function .......................................... opens and closes at every half cycle
Type ................................................ inductive proximity switch NO, PNP
Voltage ................................................................................. 12 – 48 V DC
Current max. ................................................................................ 200 mA
Short-circuit strength
LED for output status
Body ......................................................................................... tubular, Ø 8
Connection ......................................................................................... M 12
Level monitoring
Type .............................................................................................. NO + NC
Voltage max. ............................................................................... 240 V AC
250 V DC
Current max. ................................................................. 3 A for 240 V AC
0,27 A for 250 V DC
Ambient temperature ....................................................... –25 to +50 °C
Protection ........................................................................................... IP 65