SKF KFG Series Configuration guide

1-0358-US1-3034-EN
Reservoir pump units of the
KFG series (S)(C)
for grease lubrication systems in rotary application
General Information
Pump units of the KFG, KFGS and KFGC (CAN
bus) series are electrically driven reservoir
pump units available with or without an inte-
grated control unit. A patented grease follo-
wer system allows the pump units to be used
in rotary applications, so the pump is always
able to supply on-demand lubrication to cen-
tralized lubrication systems with progressive
feeders and to single-line systems. The pump
units differ in terms of the size and type of lu-
bricant reservoir, the lubricant filling and their
control and function monitoring.Powerful
CAN bus versions allow one unit and a special
valve to supply up to four independent zones
according to demand.
Application
Pump units of the KFG, KFGS and KFGC (CAN
bus) series are utilized in grease lubrication
systems. Fields of application include, for exa-
mple, wind energy systems and special pur-
pose machinery.
Advantages
Pump units are fully functional in rotary•
application (360°)
Sturdy design with 1 to 3 pump elements•
Compact and reliable•
High-pressure technology with grease•
follower plate and therefore suitable for
standard greases up to NLGI Grade 2 and
low working temperatures
Control unit with memory and system•
monitoring function
Equipped on request with CAN bus control•
for integrating machine controls
Extensive accessories program with pres-•
sure relief valves, fill level switches, etc.

Pump units of the KFG, KFGS and KFGC series for rotary application
2 1-3034-EN
Distinguishing features of the
pump units
Pump units of the KFGS and KFGC (CAN bus)
series are based on the KFG series, a reser-
voir pump unit without an integrated control
unit.
Unit components
Item Description
1 Assembly holes
2 Lubricant reservoir
3 Pump element
4 Pressure regulating valve
5 Filler socket
6 Electrical connection
7 General control unit/CAN bus display
8 Pushbutton
9 Inputs and outputs (CAN bus version)
10 CAN bus plug
6
:56
1
2
35
4
678
:56B
54
3
2
1
:562
20=1db
54
3
6
9
10
7
Table of contents
Distinguishing features of the pump units 2
KFG pump unit 3
KFGS pump unit 3
KFGC (CAN bus) pump unit 3
Design 4
Pump housing 4
Assembly holes 4
Lubricant reservoir 4
Pump element 4
Pressure regulating valve 4
KFGS control unit 4
KFGC (CAN bus) 4
Functional description of progressive system
with KFG pump unit 5
Functional description of progressive system
with KFGS pump unit 5
Functional description of progressive system
with KFGC (CAN bus) pump unit 5
Functional description of single-line system
with KFG pump unit 6
Functional description of single-line system
with KFGS pump unit 6
Functional description of single-line system
with KFGC (CAN bus) pump unit 6
KFG pump unit for rotary application 7
Fill level monitoring 9
Fill level switch E 9
Fill level switch F 9
Fill level switch H 9
Fill level switch P 10
Quasi-analoglllevelswitchT 10
Pressure regulating valves 11
for progressive systems 11
Pressure relief valve with integrated
pressure regulating valve 11
Pump elements 12
General conditions for
electrical connections 12
KFGS pump unit for rotary application 13
IG502-I integrated control and
monitoring unit 15
Fill level monitoring 16
Fill level switch E 16
Fill level switch F 16
Fill level switch H 16
Fill level switch P 17
Quasi-analoglllevelswitchT 17
Pressure regulating valves 18
Pressure relief valve with integrated
pressure regulating valve 18
Pump elements 19
General conditions for electrical
connections 19
Connectivity for timer operation without
systemmonitoring(andlllevelcontrol) 20
Connectivity for timer operation with
systemmonitoring(andlllevelcontrol) 20
Connectivity for timer operation with
systemmonitoring,lllevelcontrol,
piston detector and indicator light 20
KFGC (CAN bus) pump unit with integrated
control unit for rotary application 21
LC-CAN5000 integrated CAN bus
control unit with display 23
Connections 24
Connectivity 24
General conditions for electrical
connections 24
Accessories 25
Pressure regulating valves with T connector
output for progressive systems 25
Pressure gauge 25
Connecting piece for pressure gauge 25
Pressure gauge screw connection with
gasket 25
Filling cylinder with connecting piece 26
Filling device with quick-action coupling 26
Topping-up pumps 26
Explanation of order codes 27

Pump units of the KFG, KFGS and KFGC series for rotary application
31-3034-EN
KFG pump unit
The KFG pump has three lubricant outlets for
connecting up to three independent zones. A
separate pump element is required for each
outlet.
Up to five pump elements with different deliv-
ery volumes are available so the delivery rate
can be adjusted to the requirements of the
individual zones.
Pumps of the KFG series for rotary application
differ from those for industrial use in that
they integrate a patented grease follower sys-
tem. This ensures continuous grease supply
to the pump in every situation.
The pump fill level is monitored by a fill level
switch attached on the cover. Depending on
the switch design, 1 to 3 switching points can
be monitored. "T" control can optionally be
used to provide a continuous fill level signal.
The pump is available in various voltage de-
signs.
There may be restrictions on the components
depending on the particular conditions in the
field of application.
This also applies to KFGS and KFGC (CAN bus)
pump units.
KFGS pump unit
Pump units of the KFGS series are reservoir
pump units with an integrated control unit
based on the KFG.
The KFGS pump unit is controlled by the
IG502-I integrated control and monitoring
unit, which can operate based on time or
(pulse) load and with or without a monitoring
function.
This control unit provides the following
advantages:
Non-volatile memory with PIN code•
protection
Recording of remaining intervals and•
remaining lubrication times
Recording of fault notifications (diagnostics•
memory)
Data backup in case of voltage failure•
Connectivity for external pushbutton•
Connectivity for inductive piston detector•
or pressure switchInterval time and contact
time can be adjusted independently, inclu-
ding on monitored systems
Easy electrical connection using plug•
connectors
Interval times (timer), interval pulses (coun-
ter) and pump cycle times (contact) can be
entered through a display. A piston detector is
used to monitor the feeding operation on pro-
gressive systems; a pressure switch is used
for single-line systems. The KFGS pump unit
is available in various reservoir and voltage
designs.
In addition to the fill level versions that are to
be attached by the customer, the signal on
switch version "E" can also feed into the
IG502-I control and monitoring unit that is
integrated into the pump.
KFGC (CAN bus) pump unit
Pump units of the KFGC (CAN bus) series are
pump units from the KFG series with an inte-
grated CAN bus control unit.
The LC-CAN5000 control units offer the
following special features:
CAN bus interface (SAE J1939), which•
allows units to be seamlessly integrated
into the CAN bus networks.
The lubrication system can be monitored,•
operated and configured through the
CAN bus.
There is also the option of configuring and in-
dependently operating the pump unit via the
IRDA interface.
The control unit is still able to control up to
four independent zones and to supply them
from a single pump unit. To achieve this capa-
bility, electric switch valves which are con-
trolled based on the parameters set for each
individual lubrication zone are placed in the
main line. The control unit has up to four so-
lid-state switching outputs for this purpose.
Aside from valve control, the outputs can also
be configured as digital outputs for other pur-
poses. In addition to the above-mentioned
outputs, up to four digital inputs are available,
e.g. for monitoring piston detectors, pressure
switches or other switching contacts.

Pump units of the KFG, KFGS and KFGC series for rotary application
4 1-3034-EN
KFGS control unit
Pump units of the KFGS series are equipped
with an IG502-2-I integrated control unit
with a control display. Parameters for interval
times (timer), interval pulses (counter) and
pump cycle times (contact) can be entered
through the control unit.
Design
Pump units of the KFG, KFGS and KFGC (CAN
bus) series are characterized by their compact
construction and are divided into the assem-
blies for pump housing, lubricant reservoir,
control unit and fill level monitoring. A short
description of the individual assemblies fol-
lows below.
Pressure regulating valve
A pressure regulating valve can be attached to
the pump unit on progressive systems to pre-
vent excessive operating pressure in the lu-
brication system in case of a fault. If the oper-
ating pressure exceeds the cracking pressure
of the pressure regulating valve, the valve
opens and the lubricant flows back (on ver-
sions with a return line) into the lubricant
reservoir.
75 0,4
200 0,4
Ø 9,0
Assembly holes
A mounting flange with assembly holes is
present on the back of the pump housing on
all pump versions.
2
1
3
Pump element with pressure regulating valve
Pump element
The pump element(s) meter the lubricant
then pass it to the downstream lubrication
points or feeders. Five different pump ele-
ments with a delivery volume ranging from
0.8 to 5 cm3/min. are available to provide the
required quantity of lubricant.
Lubricant reservoir
The lubricant reservoir is available in 4 kg, 6
kg, 8 kg, 10 kg and 12 kg sizes. The reser-
voirs are made of transparent plastic and
have fill level markings that allow the fill level
to be monitored visually. Fill level switches
and/or sensors can also be attached.
Pump housing
The pump housing contains, among other
things, the pump drive, control unit (KFGS)
and three lubricant outlets for installing a
maximum of three pump elements. One pres-
sure regulating valve can be attached to each
pump element. When used in single-line sys-
tems, a pressure relief valve with an integrat-
ed pressure regulating valve is attached to the
pump element (max. 1 single-line system per
pump).
A conical head nipple can optionally be at-
tached to the pump housing using the alter-
native connections to fill the pump. A filler
socket or grease return can also be attached.
A display and control screen is mounted on
the front side of the KFGS design, while the
KFGC (CAN bus) design has a display at-
tached. An IRDA interface is integrated into
this, which can optionally be used to program
the pump.
Depending on the pump version and voltage
design, the electrical connections are located
on the left front and/or the underside of the
pump housing.
Assembly holes
Pump element
Pressure
regulating valve
R
A
P
R
M14 x 1,5
PA
P
A
P
M14 x 1,5
R
R
A
Pressure regulating valve with optional lubricant nipple
KFGS display and control screen
KFGC (CAN bus)
Pump units of the KFGC (CAN bus) series are
equipped with an integrated CAN bus board
with a control display.
The display shows the operating voltage,
pump cycle time, network communication,
cycle indicator and any fault notifications.
KFGC (CAN bus) display
Alternative
connections

Pump units of the KFG, KFGS and KFGC series for rotary application
51-3034-EN
20=1dbB049 ("(
Functional description of progressive
system with KFG pump unit
A general progressive feeder system con-•
sists of the following components: Pump
unit with pump element and pressure
regulating valve
Lubricant lines, consisting of main and•
possibly branch lines
Progressive feeders•
When the pump motor is turned on, the pis-
ton pump delivers lubricant from the lubricant
reservoir to the lubricant outlet. The pump el-
ement attached to the outlet delivers the lu-
bricant further, into the downstream main
line. The lubricant flows through the main line
to the progressive feeder. There, the lubricant
is distributed according to the volume re-
quired by the lubrication point being sup-
plied.
In progressive systems with a master feeder
and secondary feeder, the lubricant coming
from the pump unit is delivered to the master
feeder. The master feeder distributes the
lubricant to the secondary feeders according
to their individual volume requirements. From
there, the lubricant flows to the lubrication
points.
Example of progressive system with KFG pump unit
8
7
6
4
5
3
2
1
Functional description of progressive
system with KFGS pump unit
The general functional description for progres-
sive systems with a KFG pump unit also ap-
plies for the design with KFGS pump control.
The control unit integrated into the pump
housing allows the following additional con-
figuration, monitoring and connectivity op-
tions:
Interval time and contact time can be•
adjusted independently, including on moni-
tored systems
Recording of remaining intervals and•
remaining lubrication times
Data backup in case of voltage failure•
Non-volatile memory with PIN code•
protection
Connectivity for inductive piston detector to•
monitor the feeder function
Connectivity for external pushbutton•
Internal fill level monitoring (E control);•
lubrication cycle and fault notification
remain on display in case the level falls
below minimum
Example of progressive system with KFGS pump unit
10
7/8
6
4
9
3
2
1
Progressive system with KFGC (CAN bus) pump unit
Progressive system with KFG pump unit
1 KFG unit
2 Electrical fill level monitoring
3 Pump element with pressure
regulating valve
4 Electrical pump connection
5 Lubricant line
6 Master feeder
7 Secondary feeder
8 Lubrication points
KFGS progressive system with piston detector
1 KFGS unit
2 Electrical fill level monitoring
3 Pump element with pressure
regulating valve
4 Electrical pump connection
5 Fault indicator light
6 Lubricant line
7 Master feeder
8 Piston detector
9 Secondary feeder
10 Lubrication points
5
7
5
66
9
5
Functional description of progressive
system with KFGC (CAN bus) pump
unit
The general functional description for pro-
gressive systems with a KFGS pump unit also
applies for the design w ith CAN bus pump
control. The integrated LC-CAN5000 control
unit permits the lubrication zone of a pro-
gressive feeder system to be distributed into
individual lubrication zones for which individ-
ual parameters (e.g. contact and interval
times) can be set. Up to four lubrication sec-
tions can be installed in total. To distribute the
lubricant, a corresponding number of electric
switch valves is installed in the lubricant line
leading from the pump element. A valve is
opened as soon as the control unit starts a
pump cycle period for the corresponding lu-
brication segment. The pump can only pro-
vide one lubrication segment with adequate
lubrication, so it must be ensured that only
one valve is opened during operation. This is
handled by the control unit in automatic and
semiautomatic operation.
A 5/4 directional solenoid valve can optionally
be used in place of single valves.

Pump units of the KFG, KFGS and KFGC series for rotary application
6 1-3034-EN
Functional description of single-line
system with KFG pump unit
A general single-line system consists of the
following components: pump unit with pump
element, pressure relief valve with integrated
pressure regulating valve, main lubricant line
and single-line distributors. When the pump
motor is turned on, the piston pump delivers
lubricant from the reservoir to the lubricant
outlet. The pump element attached to the
outlet meters the lubricant and delivers it fur-
ther through the pressure relief valve at-
tached to the pump element on to the main
line. The lubricant flows through the main line
to the single-line distributors, where it is me-
tered and passed to the lubrication points.
This is performed during or after the pump
cycle time, depending on the type of feeders
used (prelubrication or relubrication feeders).
The
pressure relief valve switches after metering
is complete. After the main line has been re-
lieved, the single-line distributors are again
premetered and the pump unit is now pre-
pared for another lubrication cycle.
Single-line system with KFG pump unit
1 KFG unit
2 Main line
3 Pressure switch
4 Pressure relief valve
5 Single-line distributor
Example of single-line system with KFG pump unit
Functional description of single-line
system with KFG pump unit
The general functional description for single-
line systems with a KFG pump unit also ap-
plies for the design with KFGS pump control.
The control unit integrated into the pump
housing allows the following additional
conguration,monitoringandconnectivity
options:
Interval time and contact time can be•
adjusted independently, including on moni-
tored systems
Recording of remaining intervals and•
remaining lubrication times
Recording of fault notifications (diagnostics•
memory)
Data backup in case of voltage failure•
Non-volatile memory with PIN code•
protection
Connectivity for pressure switch•
Fill level monitoring, lubrication cycle and•
fault notification remain on display in case
the level falls below minimum
Example of single-line system with KFGS pump unit
Single-line system with KFGS pump unit
1 KFGS unit
2 Control/display
3 Main lubricant line
4 Pressure switch
5 Pressure relief valve
6 Single-line distributor
Functional description of single-line
system with KFGC (CAN bus) pump
unit
The general functional description for single-line
systems with a KFG pump unit also applies for
the design with CAN bus pump control.The
integrated LC-CAN 5000 control unit permits
the lubrication zone of a single-line distributor
system to be distributed into individual lubri-
cation zones for which individual parameters
(e.g. contact and interval times) can be set.
Up to four lubrication zones can be installed
in total. To distribute the lubricant, a corre-
sponding number of electric switch valves is
installed in the lubricant line leading from the
pump element. A valve is opened as soon as
the control unit starts a pump cycle period for
the corresponding lubrication segment. The
pump can only provide one lubrication seg-
ment with adequate lubrication, so it must be
ensured that only one valve is opened during
operation. This is handled by the control unit
in automatic and semiautomatic operation.
When CAN commands are used for control,
the valve opening must be ensured by select-
ing the appropriate contact and interval times
or by using appropriately programmed pro-
cesses in the external lubrication program
which switches the valves in a carefully coor-
dinated sequence so that only one lubrication
zone is activated at a time.
5
4
3
21
5
5
6
4
3
2
1
6
5
6

Pump units of the KFG series for rotary application
71-3034-EN
4 kg, 6 kg and 8 kg KFG pump unit
for rotary application
Dimensions
KFG pump unit, reservoir sizes 4 kg, 6 kg and 8 kg
Delivery data
Pump element Delivery rate Maximum flow pressure Max. permis. pressure
at pump element
[cm3/min.] [mbar at NLGI 2] [bar]
KFG1.U0 5.0 450 200
KFG1.U1 2.5 700 300
KFG1.U2 1.8 700 300
KFG1.U3 1.3 700 300
KFG1.U4 0.8 700 300
4 kg 6 kg 8 kg
with 24 VDC
with 230 VAC
Ø9
643 (Reservoir size 8 kg )
305
157
605 ( Reservoir size8 kg )
535 (Reservoir size 6 kg )
27
450 (Reservoir size 4 kg )
75
Ø 9
78.5
266.5
13200 217.5

Pump units of the KFG series for rotary application
8 1-3034-EN
10 kg and 12 kg KFG pump unit
for rotary application
Dimensions
KFG pump unit, reservoir sizes 10 kg and 12 kg
Delivery data
Pump element Delivery rate Maximum flow pressure Max. permis. pressure
at pump element
[cm3/min.] [mbar at NLGI 2] [bar]
KFG1.U0 5.0 450 200
KFG1.U1 2.5 700 300
KFG1.U2 1.8 700 300
KFG1.U3 1.3 700 300
KFG1.U4 0.8 700 300
with 24 VDC
with 230 VAC
325 (Reservoir size 12kg) 325
147
Ø9
20200
927 (Reservoir size 12kg)
305
157
221
35
Ø9
Ø14
807 (Reservoir size 10kg)
27
78.5
273.5
280280 (Reservoir size 10kg)
10 kg 12 kg

Pump units of the KFG series for rotary application
91-3034-EN
Fill level monitoring
Technical data, design E
Medium...............................NLGI Grade 2 greases
Fill level monitoring
Function .............................Protective ground
Form of contact ................ChangeoverSwitching
capacity, max......................60 W/VA
Switching voltage, max.....230 V DC/AC
Switched current, max. ...1 A
Connection diagram .........EN 175301-803
plug Protection class ........IP 65
3
2
1
Switch position at
minimum
Switch position
above minimum
3
2
1
Fill level switch E
Fill level switch F
Connector pin assignment, design E
Pin Description
1 = + Supply voltage
2 = Signal output
"above minimum"
3 = Signal output "minimum"
= PE Protective earth
Technical data, design F
Medium......................... NLGI Grade 2 greases
Fill level monitoring
Function ....................... Reed contact
Form of contact .......... NO-contact/NC contact
Lubricant at "Early warning min." setting
4 kg Pump unit..............1.0 kg
6kg Pump unit ..............1.5 kg
8kg Pump unit ..............2.0 kg
10kg Pump unit ..............2.0 kg
12kg Pump unit ..............2.0 kg
Switching capacity, max. 60 W/VA
Switching voltage, max... 230 V DC/AC
Switched current, max. . 1 A
Connection diagram ....... EN 175301-803 plug
Protection class ............... IP 65
Connector pin assignment, design F
Pin Description
1 = + Supply voltage
2 = Signal output "Maximum"
3 = Signal output "Minimum"
= PE Protective earth
Fill level switch E
Fill level switch F
Technical data, design H
Medium............................NLGI Grade 2 greases
Fill level monitoring
Function .......................... Reed contact
Form of contact NO-contact/
NC contact/
changeover
Lubricant at "Early warning min." setting
4 kg Pump unit..............1.0 kg
6 kg Pump unit..............1.5 kg
8 kg Pump unit..............2.0 kg
10 kg Pump unit..............2.0 kg
12 kg Pump unit..............2.0 kg
Switching capacity, max.. 60 W/VA
Switching voltage, max. 10-30 V DC/AC
Switched current, max. . 1 A
Connection diagram .......DIN 43 651 plug
Protection class ...............IP 65
Fill level switch H
Switch position at
minimum
Switch position at
maximum
1
6
4
3
+
5
1
6
4
3
+
5
Switch position at early
warning minimum
1
6
4
3
+
5
Fill level switch H
Connector pin assignment, design H
Pin Description
5 = + Supply voltage
3
2
1
Switch position at
minimum
3
2
1
Switch position
between minimum
and maximum
Switch position at
maximum
3
2
1

Pump units of the KFG series for rotary application
10 1-3034-EN
Fill level monitoring
Fill level switch P
Fill level switch P
Technical data, design P
Medium...........................NLGI Grade 2 greases
Fill level monitoring
Function .........................Protective ground
Form of contact ............NO-contact/changeover
Switching capacity, max.60 W/VA Switching
voltage, max...................230 V DC/AC
Switched current, max. 1 A
Connection diagram .....EN 175301-803 plug
Protection class .............IP 65
Connector pin assignment, design P
Pin Description
1 = + Supply voltage
2 = "Maximum"
3 = "Minimum"
Technical data, design T
Medium..........................NLGI Grade 2 greases
Current output .............KFG/KFGS 4-20 mA
KFGC 0.4-3.6 mA
Connection diagram ....EN 175301-803 plug
Protection class ............IP 65
Quasi-analog fill level switch T
Quasi-analog fill level switch T Connector pin assignment, design T
Pin Description
1 = + I
2 = - I
Switch position at
early warning
minimum
Switch position at
minimum
1
2
3
1
2
3
=
Fill
level
1
2
DC 7,5 .... 30 V
4 ... 20 mA