SKF ECP User manual

EN
for single-line centralized lubrication systems
ECP Electrically driven cartridge pump unit
Version 01
Original installation instructions following machinery
directive 2006/42/EC for incomplete machines with
corresponding operating instructions
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EC Declaration of incorporation following machinery directive 2006/42/EC, annex II, part 1 B
The manufacturer SKF Lubrication Systems Germany GmbH, Berlin Facilities Motzener Straße 35/37 12277 Berlin Germany
hereby declares the correspondence of the partly completed machinery
Designation: Electrically driven cartridge pump unit
Type: ECP
Year of construction: See type identification plate
complies with the following basic safety and health requirements of the EC machinery directive 2006/42/EC at the time when first being launched in the
market.
1.1.2 · 1.13 · 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 special technical documents were prepared following Annex VII part A of this directive. Upon justifiable request, these special technical documents can be
forwarded electronically to the respective national authorities. The person empowered to assemble the technical documentation on behalf of the manufacturer is
the head of standardization, See manufacturer's address.
Furthermore, the following directives and harmonized standards were applied in the respective 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 2011 DIN EN 60034-1 2011 DIN EN 61000-6-2 2006 DIN EN 61000-6-3 2011
Amendment 2013 Amendment 2015 Amendment 2011 Amendment 2012
DIN EN ISO 809 2012
DIN EN ISO 50581 2013
The partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with
the previsions of machinery directive 2006/42/EC and any other applicable directives.
Berlin, 29 January 2016
EN EC Declaration of incorporation
Jürgen Kreutzkämper
Manager R&D Germany
SKF Lubrication Business Unit
Dr.-Ing. Holger Schmidt
Manager Development Center Berlin
SKF Lubrication Business Unit
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Legal disclosure EN
Legal disclosure
The original installation instructions follow-
ing machinery directive 2006/42/EC are
part of the described product and must be
kept at an accessible location for further use.
Warranty
The instructions do not contain any infor-
mation on the warranty. This can be found
in the general terms and conditions. This
can be found on:
www.skf.com/lubrication.
Copyright/ Integration of the instructions
© SKF Lubrication Systems Germany GmbH
All rights reserved.
These instructions are copyright-protected.
The integration of the content into the
manufacturer's documentation of the ma-
chine, into which the product shall be inte-
grated, is expressly allowed. This also in-
cludes the creation of training material for
internal, non-commercial purposes. Any
other use without the written consent of
the copyright holder - of whatever kind - is
prohibited and is regarded as a violation of
copyright.
EN
Manufacturer's service addresses
Walldorf Facilities
Central Customer Service
Heinrich-Hertz-Str. 2-8
69190 Walldorf
Germany
Phone: [phone]
Fax: [phone]
Berlin Facilities
Central Customer Service
Motzener Straße 35/37
12277 Berlin
Germany
Phone [phone]
Fax [phone]
Hockenheim Facilities
Central Customer Service
2. Industriestraße 4
68766 Hockenheim
Germany
Phone [phone]
Fax [phone]
E-mail: Lubrication-german[email protected]om
www.skf.com/lubrication
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Installation instructions
machinery directive 2006/42/EC 1
Explanation of symbols and signs 6
1. Safety instructions 8
1.1 General safety instructions 8
1.2 General behaviour when handling
the product 8
1.3 Qualified technical personnel 9
1.4 Electric current hazard 10
1.5 Hazard from system pressure or
hydraulic pressure 10
1.6 Operation 10
1.7 Assembly, maintenance,
malfunctions, shutdown, disposal 11
1.8 Intended use 11
1.9 Foreseeable misuse 12
1.10 Disclaimer of liability 13
1.11 Referenced documents 13
1.12 Existing residual risks 14
2. Lubricants 17
2.1 General information 17
2.2 Selection of lubricants 17
2.3 Approved lubricants 18
2.4 Lubricants and the environment 19
2.5 Lubricant hazard 19
3. Overview 20
3.1 Product code 21
4. Assembly 22
4.1 General information 22
4.2 Set-up and attachment 22
4.2.1 Minimum assembly dimensions 23
4.3 Connection dimensions, mounting
bores and minimum assembly
dimensions 24
4.4 Assembly of the product 25
4.5 Lubricant feed line connection 26
4.6 Mounting of the lubrication lines
by means of SKF plug-in connector 27
4.7 Electrical connection 28
4.7.1 General information 28
4.7.2 Electrical characteristics,
version 24 V DC 30
4.8 Vent centralized lubrication system 31
4.9 Notes related to the type
identification plate 33
4.10 Notes related to the CE marking 33
EN
Table of contents
Table of contents
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Operating instructions 35
1. Safety instructions 36
1.1 General information 36
2. Lubricants 36
3. Delivery, returns and storage 36
3.1 Checking the delivery 36
3.2 Returns 37
3.3 Lubrication units 37
3.4 General information 37
4. Assembly 37
4.1 General notes related to assembly 37
5. Design and function 38
5.1 General information 38
5.2 Set-up of the ECP
cartridge pump unit 38
5.3 Functional description 38
6. Operation, shutdown and disposal 40
6.1 General information 40
6.2 Pushbutton DK 40
6.3 Screwing in the lubricant
cartridge/ change of cartridge 41
6.4 Initial start-up 42
6.5 Start-up 43
6.6 Temporary shutdown 43
6.7 Shutdown and disposal 43
7. Maintenance 44
7.1 General information 44
7.2 Maintenance schedule 45
7.3 Service 45
8. Troubleshooting 46
8.1 Start-up, product and
system failures 47
9. Technical data 48
9.1 Technical characteristics 48
10. Spare parts 49
11. Accessories 50
EN
Table of contents
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EN
Possible symbols
Meaning
Note
Electrical component hazard, elec-
trical shock hazard
Slipping hazard
Hazard from hot components
Hazard from hot surface
Hazard from unintentional intake
Crushing hazard
Hazard from suspended load
Pressure injection hazard
Explosion-protected component
Electrostatically sensitive
components
Wear personal protective equip-
ment (goggles)
Protect (lock) the starting device
against unintentional activation
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 these operating instructions.
Please read these instructions thoroughly
and heed the warning and safety notes.
Information symbols within treatises
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 imminent
WARNING Serious injury possible
CAUTION Minor injury possible
ATTENTION Property damage possible
Symbol
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EN
Markings attached to the ECP must be ob-
served and kept in fully legible conditions.
Explanation of symbols and signs
Abbreviations and conversion factors
Abbreviations
re. regarding oz. Ounce
approx. approx. psi pounds per square inch
°C degrees Celsius hp horse power
s second lb. pound
dB (A) sound pressure level sq.in. square inch
i.e. that is kp kilopond
etc. et cetera cu.in cubic inch
poss. possibly 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
if appl. if applicable gal. gallon
etc. et cetera
a.a.r. as a rule
Ø diametre Conversion factors
incl. including Length 1 mm = 0.03937 in.
K Kelvin Area 1 cm² = 0.155 sq.in
kg kilogram Volume 1 ml = 0.0352 fl.oz.
rh relative humidity 1 l = 2.11416 pints (US)
kW kilowatt Mass 1 kg = 2.205 lbs
l litre 1 g = 0.03527 oz.
min minute Density 1 kg/cm³ = 8.3454 lb./gal (US)
max. maximum 1 kg/cm³ = 0.03613 lb./cu.in.
min. minimum Force 1 N = 0.10197 kp
mm millimetre Speed 1 m/s = 3.28084 fpsec.
ml millilitre 1 m/s = 2.23694 mph
N Newton Acceleration 1 m/s² = 3.28084 ft./s²
Nm Newtonmeter Pressure 1 bar = 14.5 psi
Temperature °C = (°F-32) x 5/9
Output 1 kW = 1.34109 hp
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ENEN
1. Safety instructions
1.1 General safety instructions
The owner must ensure that the installation
instructions have been read by any persons
entrusted with works on the product or by
those persons who supervise or instruct
the before-mentioned group of persons. In
addition, the owner must also ensure that
the relevant personnel are fully familiar with
and have understood the contents of the
instructions.
The installation instructions must be kept
at hand together with the product for future
reference.
The installation instructions are part of the
product and must accompany the product
when selling it. The described product was
manufactured according to the state of the
art. Risks may, however, arise from its usage
and may result in harm to persons or damage
to material assets.
Any malfunctions which may affect safety
must be remedied immediately. In addition
to the installation instructions, general
statutory regulations and other regulations
for accident prevention and environmental
protection must be observed.
1.2 General behaviour when handling
the product
o The product may only be used in aware-
ness of the potential dangers, in proper
technical condition, and according to the
information in these instructions.
o Technical personnel must familiarize
themselves with the functions and
operation of the product. The specified
assembly and operating steps and their
sequences must be observed.
o Any unclear points regarding proper
condition or correct assembly/operation
must be clarified. Operation is prohibited
until issues have been clarified.
o Keep unauthorized persons away from
the product.
o Observe all relevant precautionary opera-
tional measures and instructions for the
respective work.
o Clearly define and observe responsibilities
for different activities. Uncertainty seriously
endangers safety.
o Do not remove, modify or otherwise affect
safety-related protective and emergency
devices in their function and check them
for completeness and function at regular
intervals.
If protective and safety equipment has to
be dismantled, it must be reassembled
immediately after finishing the work, and
then checked for correct function.
o Remedy occurring faults in the frame of
responsibilities. Immediately inform your
superior in the case of faults beyond your
competence.
o Wear personal protective equipment
always.
o When handling lubricants or operating
materials, adhere to the respective safety
data sheets.
1. Safety instructions
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1
ENEN
1.3 Qualified technical personnel
Only qualified technical personnel may in-
stall, operate, maintain, and repair the prod-
ucts described in this document.
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 definitions of
qualified technical personnel apply for coun-
tries outside the scope of DIN VDE 0105 or
IEC 364.
The operator of the final product is re-
sponsible for assigning tasks and areas of
responsibility.
The personnel must be trained and in-
structed, if they do not possess the required
knowledge.
Product training can also be performed by
SKF in exchange for costs incurred.
1. Safety instructions
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ENEN
1.5 Hazard from system pressure or
hydraulic pressure
1.4 Electric current hazard
WARNING
Electric shock
Assembly, maintenance, and
repair works may be performed
by qualified and authorized
personnel.
Prior to performing work, the
product must be disconnected
from the power supply.
Thereby the local connection con-
ditions and legal prescriptions (e.g.
DIN, VDE) have to be observed.
WARNING
System pressure
Hydraulic pressure
Lubrication systems are pressur-
ized during operation. They must
be depressurized before starting
assembly, maintenance, modifica-
tion or repair works.
1.6 Operation
The following must be observed when
working on the product.
o All information within these instructions
and the information within the referenced
documents.
o All laws and regulations to be complied
with by the user.
1. Safety instructions
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1
ENEN
All relevant persons (e.g. operating personnel,
supervisors) must be informed of the activity
prior to starting any work. Observe the pre-
cautionary operational measures and work
instructions.
o Ensure through suitable measures that
movable or detached parts are immobi-
lized during the work and that no limbs
can be caught in between by inadvertent
movements.
o Assemble the product only outside of the
operating range of moving parts, at an
adequate distance from sources of heat.
o Prior to performing work, the product
and the machine or system in which the
product is or will be integrated must be
depressurized and secured against unau-
thorized activation.
o Carry out all works on electrical compo-
nents using voltage insulated tools only.
o Fuses must not be bypassed. Always re-
place fuses by such of the same type.
o Ensure proper grounding of the product.
o Undertake drilling at non-critical, non-
load bearing parts only.
o Other units of the machine must not be
damaged or impaired in their function by
the installation of the centralized lubrication
system.
o No parts of the centralized lubrication
system must be subjected to torsion,
shearing or bending.
o When working with heavy components,
use adequate lifting devices.
o Avoid mixing up or wrong assembly of
disassembled parts. Mark these parts
accordingly.
1.7 Assembly, maintenance, malfunctions, shutdown, disposal
The electrically driven cartridge pump unit
ECP has been designed to provide single-
line centralized lubrication systems with
lubricant via SKF lubricant cartridges.
The ECP supplies SKF approved fluid
greases based on mineral oils as well as
environmentally sound and synthetic fluid
greases of NLGI class 00 to 000, further-
more mineral oils as well as environmentally
sound and synthetic oils with an admissible
operating viscosity of 20 to 1500 mm2/s,
following operating mode:
S3 15% ED (according to DIN EN
60034-1).
Temporarily and occasionally the cartridge
pump unit may be operated beyond the
designated operating mode S3 15% ED, for
example, to fill the lubrication lines or to
vent the cartridge pump unit (after chang-
ing the cartridge). To do so a temporary and
occasional operating mode S1 100% ED is
admitted, whereby the maximum pump run
time must not exceed 15 minutes.
1. Safety instructions
1.8 Intended use
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ENEN
After a temporary operating mode S1 100%
ED a pause time of at least 10 minutes
must be provided (cooling down of the elec-
trical pump components).
Failure to comply with the prescriptions
regarding a temporary and occasional per-
manent operation may result in a damage
of the ECP and represents a purpose other
than the intended.
Permanent operation is triggered via the
pushbutton on the cartridge pump unit or
by a corresponding filling program (recom-
mended) of the PLC control of the machine
of the cartridge pump unit.
The fluid greases used must be compatible
with plastic and NBR elastomers.
When using synthetic or biodegradable fluid
greases or oils, prior approval by SKF is
required.
The electrically driven cartridge pump
unit ECP has to lubricant outlets that can
be used individually or together (observe
layout guidelines of centralized lubrication
systems!).
To ensure a determined allocation of quanti-
ties, particularly when using both outlets in
parallel, the outlet(s) always has (have) to be
connected to lubricant metering devices.
Use is permitted exclusively for ECP-
approved lubricants provided in SKF single-
use cartridges.
Any other or exceeding use is considered to
be improper use.
1. Safety instructions
1.9 Foreseeable misuse
Any usage of the product differing from
the aforementioned conditions and stated
purpose is strictly prohibited. It is expressly
forbidden:
o to disregard the operating mode regard-
ing temporary and occasional permanent
operation.
o to use the product in an explosion protec-
tion zone
o to supply, transport, or store hazardous
substances and mixtures in accordance
with annex I part 2-5 of the CLP regulation
(EG 1272/2008).
o to supply, transport, or store gases,
liquefied gases, dissolved gases, vapours,
and fluids whose vapour pressure ex-
ceeds normal atmospheric pressure
(1013 mbar) by more than 0.5 bar at
the maximum admissible operating
temperature.
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1
ENEN
1. Safety instructions
1.11 Referenced documents
In addition to these instructions, the fol-
lowing documents must be observed by the
respective target group:
o Operational instructions and release
provisions.
o Instructions of the suppliers of purchased
parts.
o Safety data sheet (MSDS) of the lubricant
or material used.
o Project planning documents and other
relevant documents, if any.
The operator must supplement these docu-
ments with the relevant applicable national
regulations of the country of use.
If the product is sold or transferred, any as-
sociated documents must be passed on to
the subsequent operator as well.
1.10 Disclaimer of liability
The manufacturer shall not be held re-
sponsible for damages caused by:
o non-observance of these instructions
o using lubricants or material not suitable
for the type of pump.
o contaminated or inappropriate lubricants.
o the installation of non-original SKF
components.
o inappropriate usage.
o faulty assembly, setting, or filling.
o improper or late response to mal-
functions.
o
non-compliance with maintenance
intervals.
o unauthorized modification of system
components.
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ENEN 1. Safety instructions
1.12 Existing residual risks (residual risk evaluation)
Residual risks Remedy
Installation life cycle
People slipping due to floor contamination
with spilled or leaked lubricant. • Exercise caution when changing the cartridge.
• Bind and remove leaked or spilled lubricant immediately with a suitable agent.
• Follow the operational instructions on handling oils and contaminated parts.
Tearing or damaging of lines when installed
on moving machine parts. • If possible, do not mount onto movable parts. If this cannot be avoided, use flexible hose lines.
Life cycle - commissioning, operation
Life cycle - setting, modification
Lubricant spraying out due to incorrect
screw connection of components or lines. • Tighten all parts with appropriate tightening torques. Use suitable hydraulic screw connections
and lines for the stated pressures. Check these prior to commissioning for correct connection
and damage.
People slipping due to floor contamination
with spilled or leaked lubricant.
• Exercise caution when changing the cartridge.
• Bind and remove leaked or spilled lubricant immediately with a suitable agent.
• Follow the operational instructions on handling oils and contaminated parts.
Life cycle - fault, troubleshooting
People slipping due to floor contamination
with spilled or leaked lubricant.
• Exercise caution when changing the cartridge.
• Bind and remove leaked or spilled lubricant immediately with a suitable agent.
• Follow the operational instructions on handling oils and contaminated parts.
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1
ENEN
1. Safety instructions
Residual risks Remedy
Life cycle - maintenance
Electric shock • Disconnect the ECP from the power supply before carrying out any maintenance works.
People slipping due to floor contamination
with spilled or leaked lubricant.
• Exercise caution when changing the cartridge.
• Bind and remove leaked or spilled lubricant immediately with a suitable agent.
• Follow the operational instructions on handling oils and contaminated parts.
Life cycle - shutdown, disposal
Contamination of the environment with
lubricant and wetted parts.
• Dispose of contaminated parts following the relevant legal and operational regulations.
People slipping due to floor contamination
with spilled or leaked lubricant. • Exercise caution when changing the cartridge.
• Bind and remove leaked or spilled lubricant immediately with a suitable agent.
• Follow the operational instructions on handling oils and contaminated parts.
Life cycle - malfunctions, troubleshooting, repair, maintenance
Electrical shock due to defective connec-
tion cable • Before commissioning the ECP check the connection cable for damages.
People slipping due to floor contamination
with spilled or leaked lubricant. • Bind and remove leaked or spilled lubricant immediately with a suitable agent.
• Follow the operational instructions on handling oils and contaminated parts.
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ENEN 1. Safety instructions
Residual risks Remedy
Life cycle - shutdown, disposal
Contamination of the environment with
lubricant and wetted parts.
• Dispose of contaminated parts following the relevant legal and operational regulations.
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2
1
EN
2. Lubricants
2. Lubricants
2.1 General information
Intended use is the use of the products to
lubricate bearings and friction points with
lubricants within the physical limits that
can be found in the relevant product docu-
mentation, e.g. operating instructions and
product descriptions, e.g. technical drawings
and catalogues.
Particular attention is called to the fact that
hazardous materials of any kind, especially
those materials classified as hazardous by
CLP Regulation EC 67/548 annex I, part 2-5
may only be filled into SKF centralized lubrica-
tion systems and components and delivered
and/ or distributed with such systems and
components after consulting with and ob-
Selection of a lubricant suitable for the
lubrication task is made by the machine or
system manufacturer and/or the operator of
the machine or system in cooperation with
the lubricant supplier.
When selecting a lubricant, the type of
bearings or friction points, the expected
load during operation, and the anticipated
ATTENTION
Observe the instructions from the machine
manufacturer regarding the lubricants to
be used.
The amount of lubricant required at the
lube point is specified by the bearing or
machine manufacturer. It must be ensured
that the required lubricant volume is pro-
vided to the lubrication point. Otherwise
the lubrication point may not receive ad-
equate lubrication, which can lead to dam-
age and failure of the bearing.
2.2 Selection of lubricants
taining written approval from SKF.
All products manufactured by SKF are not
admitted for use in combination with gases,
liquefied gases, dissolved gases, vapours,
or fluids
whose vapour pressure exceeds normal
atmospheric pressure (1013 mbar) by more
than 0.5 bar at the maximum admissible
operating temperature.
Other material which is neither lubricant nor
hazardous substance may be fed only after
consultation with and written approval by
SKF.
SKF considers lubricants to be an element
of system design that must always be
factored when selecting components and
designing a centralized lubrication system.
The lubricating properties of the lubricants
are critically important when making these
selections.
ATTENTION
All SKF Lubrication Systems Germany
GmbH products may be used for their in-
tended purpose and in accordance with
the indications made in the operating in-
structions of the product only.
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EN 2. Lubricants
Please contact SKF if you have further
questions regarding lubricants. It is possible
for lubricants to be tested in the company's
laboratory for their suitability for being
pumped in centralized lubrication systems
(e.g. "bleeding").
You can request an overview of the lubricant
tests offered by SKF from the company's
service department.
The product described here can be operated
using lubricants that meet the specifications
in the technical data. Depending on the
product design, these lubricants may be oils
or fluid greases.
Mineral, synthetic, and/or rapidly biodegrad-
able oils and base oils can be used.
Consistency agents and additives may be
added depending on the operating condi-
tions.
It should be considered that in individual
cases there may be lubricants whose
properties are within permissible limit val-
ues but whose other characteristics render
them unsuitable for use in centralized
lubrication systems. For example, synthetic
lubricants may be incompatible with
elastomers.
ATTENTION
Only lubricants approved for the ECP may
be used. Unsuitable lubricants can lead to
failure of the product and to property
damage.
2.3 Approved lubricants
ATTENTION
Different lubricants must not be mixed.
Doing so may cause damage and require
costly and complicated cleaning of the
product or lubrication system. It is recom-
mended that an indication of the lubricant
in use be attached to the lubricant reser-
voir in order to prevent accidental mixing
of lubricants.
ATTENTION
If required, SKF Lubrication Systems
Germany GmbH can help customers to
select suitable components for supplying
the selected lubricant and to plan and de-
sign their centralized lubrication system.
ambient conditions must be taken into ac-
count. All economic and environmental as-
pects must also be considered.
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2
EN
2. Lubricants
2.5 Lubricant hazard
WARNING
Lubricants
The products must be leakproof.
Leaking lubricant is hazardous due
to the risk of slipping and injury.
During assembly, operation, main-
tenance and repair of centralized
lubrication systems watch out for
leaking lubricant. Leaks must be
sealed immediately.
ATTENTION
Adhere to the respective safety instructions
in the lubricant safety data sheet.
2.4 Lubricants and the environment
ATTENTION
Lubricants may pollute ground and wa-
ters. Lubricants have to be handled and
disposed of properly. Observe the regional
laws and prescriptions regarding disposal
of the lubricants.
It is important to note that lubricants are
environmentally hazardous, flammable
substances that require special precaution-
ary measures during transport, storage,
and processing. Consult the safety data
sheet from the lubricant manufacturer for
information regarding transport storage,
processing, and environmental hazards of
the lubricant that will be used.
The safety data sheet of a lubricant may be
requested from the lubricant manufacturer.
Leaking lubricant constitutes a considerable
potential risk. Leaking lubricant may result
in harm to persons or damage to material
assets.
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EN 3. Overview
Components of the ECP Fig. 1
3. Overview
2
7
6
9
5
8
Hydraulic diagram
Components of the ECP
Item Description
1ECP Pump body
2Lubricant outlet 1
with SKF plug-in connector as an option
3Lubricant outlet 2
with SKF plug-in connector as an option
4 Pump vent/
Vent screw
5 Square plug following
DIN EN 175301-803-A for
voltage supply of 24 VDC
6Pushbutton (DK)
(pressing and holding function)
7Mounting flange / wall bracket
8SKF single- use lubricant cartridge
9Connecting plug for optional
monitoring of the filling level (M12x1)
Vent screw
Outlet
4
3
1
38bars
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