FAG Motion Guard CONCEPT6 CONTROL
Contents
1. fe RS O fe KS We RS O te R 9 Ot OE Ot Ot OF OF OEOEOt OF OC Figure 15 Configuration menu settings and displays e e 000014E88 Oe Configuration sections Function Short keystroke Long keystroke Signal Go to Symbol Arrow pointing Symbol downwards Longer arrow 18 BA11 Schaeffler Group Industrial INTRO LC unit Time Outlets PIN Non adoption of changes in the respective configuration section Automatic termination of the configuration mode Special dispensing process INTRO provides information INFO and asks for the current PIN PIN entry Changes are made in the configuration menu and its sections LC time outlets PIN Key SELECT key for setting LC250 or LC500 Setting in either months weeks or days Once the maximum setting parameter has been reached the count always starts with the digit 01 except where days 00 pulse operation see page 14 The last screen contents displayed are adopted by holding down the MODE SAVE key for a long period The activation of outlets 1 to 6 is indicated by the filled squares If no FAG C6 MP DISTRIBUTOR is connected the configuration of the outlets will have no effect A personal PIN protects the settings from unauthorised access The PIN can only be changed during the very first configuration or following a PIN reset The PIN reset brief pre2. Dispensing time 1 day to 24 months Dispensing quantity per lubrication impulse 0 5 cm Operating temperature 20 C to 60 C Maximum pressure 25 bar A combination of these build up maximum values is only Hose length max 5m achievable at 5 mm inside diameter Lubricants Greases up to consistency class NLGI 2 temperatures gt 20 C Application is restricted at lower temperatures see Diagram 1 page 9 Supply voltage 15 V DC to 30 V DC Typical current consumption 120 mA Maximum switching current 1A for the fault output Connection cable 4 pin standard length 5 m Threaded connector G external G internal C ATO 0000AE9E 6 BA 11 Schaeffler Group Industrial Design Cover LC unit Drive system Connection cable Figure 4 Main components of the FAG lubricator Attention Function The lubricator components correspond to the state of technology at the time of delivery and are always regarded as operationally reliable The components see Figure 4 Cover for the drive system LC unit LC250 or LC500 with lubricant Drive system 3 comprising a geared motor pump plug for the optional lubricant distributor C6 MP DISTRIBUTOR and the electronic unit Connection cable for connecting the lubricator to the machine c
3. Ordering designation LC250 with 250 cm of special lubricant Arcanol MULTITOP LC250 with other Arcanol greases or special greases ARCALUB C6 LC250 MULTITOP Available by agreement LC500 with 500 cm of special lubricant Arcanol MULTITOP LC500 with other Arcanol greases or special greases ARCALUB C6 LC500 MULTITOP Available by agreement Cover for LC250 made from transparent plastic Cover for LC250 made from aluminium for lubricants containing ester ARCALUB C6 CAP250 Available by agreement Cover for LC500 made from transparent plastic Cover for LC500 made from aluminium for lubricants containing ester ARCALUB C6 CAP500 Available by agreement Connection cable 5 m M12 angled standard ARCALUB C6 CABLE CONTROL 5M Connection cable 10 m M12 angled accessory ARCALUB C6 CABLE CONTROL 10M Schaeffler Group Industrial BA11 25 FAG Motion Guard CONCEPT6 CONTROL Accessories All accessory parts must comply with technical requirements Figure 21 Accessories QOOOAEC2 No Designation Ordering designation Holder for ARCALUB C6 HOLDER FAG Motion Guard CONCEPT6 CONTROL Special lubricant feed line 5 m ARCALUB C6 TUBE 5M inside diameter 5 mm Straight hose connector G1 g ARCALUB C6 JOINT MP 0 SET for lubricant feed line Angled hose connector G1 g ARCALUB C6 JOINT MP 90 SET for lubricant feed line Adapter G
4. The remaining running time of the lubricator must be recalculated following one or more special dispensing processes see page 21 This also applies to deactivation in the event of extended machinery downtime It is imperative that the remaining running time calculation be recorded in the lubrication and maintenance plan The software FAG Motion Guard SELECT MANAGER makes this even easier This can be downloaded free of charge from the website www fis services com Schaeffler Group Industrial BA 11 15 FAG Motion Guard CONCEPT6 CONTROL Initial operation and use Ensure before initial operation Is the lubricator outwardly intact Is the right grease in the LC unit Is the connection cable to the machine controller in place and is the correct supply voltage 15 V DC to 30 V DC present Has the cover disk with stopper been removed from the drive Have all of the components been correctly fitted together and secured Attention Always check the settings of the lubricator before initial operation and make corrections as necessary Work exactly to the user manual Upon initial operation the pump system in the drive unit is pre filled with a universal grease After approximately ten dispensing processes this fill is drained off and replaced with the grease from the LC unit perform special dispensing processes where necessary Further steps to be taken Fit the connection cable and attach the cords to the machine contr
5. g to G1 4 ARCALUB C6 NIPPLE G3 8 G1 4 Grease cartridge 400 g for prelubrication Available by agreement with a grease gun filled with Arcanol MULTITOP Grease cartridge 400 g for prelubrication Available by agreement with a grease gun filled with other lubricants ACD ROM containing FAG Motion Guard SELECT MANAGER software lubricant quantity calculation lubrication and maintenance plan and the user manual in PDF format can be obtained on request Service The operator has the option of returning the empty lubricator to Schaeffler KG for disposal of the used parts in an environmentally friendly manner replacement of the LC unit implementation of the required settings dispensing time LC unit and outlets 26 BA11 Schaeffler Group Industrial EU Declaration of Conformity E lt gt Fac EU Declaration of Conformity In accordance with EG Machinery Directive 98 37 EG and EMC Directive 89 336EWG We hereby declare that the product described below is in conformity with the applicable health and requirements of the EU Directive in terms of its design and type and in the execution we have brought into circulation This declaration shall cease to be valid if any modification is made to the product without our agreement Product description Automatic lubricator Product name FAG Motion Guard CONCEPT6 CONTROL Type LC250 and LC500 Applicable harmonised standards EN ISO 12100 1 2003 Safety of
6. clockwise direction until the bayonet catch locks into place Make the connection to the machine controller Schaeffler Group Industrial BA11 29 Calculating the dispensing time Activating the lubricator Remaining lubricant volume display dispensing time outlet numbers PIN and error recognition Outlets 1 to 6 activated outlets FAG C6 MP DISTRIBUTOR Configuration menu Setting mode selected time dimension Volume of connected LC unit Ice crystal as flashing signal in the permissible minus temperature range and as permanent signal at less than 20 C low temperature deactivation Remaining lubricant volume as a percentage Figure 25 Display Settings on the drive FAG Motion Guard CONCEPT6 CONTROL The required grease quantity in cubic centimetres per 100 operating hours is based on the data supplied by the manufacturer for the point to be lubricated The detailed user manual contains all of the information on the required lubricant quantities the dispensing time which is dependent on the volume of the LC unit and the setting mode The software FAG Motion Guard Select Manager provides a simple way of calculating the dispensing time This can be downloaded from the website www fis services com or requested free of charge in the form of a CD ROM Apply the supply voltage 15 V DC to 30 V DC via the machine controller The remaining volume of the LC unit will appear on the displa
7. that the maximum hose length of 5 m can be used with standard grease within a temperature range of 15 C to 60 C and with low temperature grease between 0 C and 15 C Schaeffler KG accepts no liability for applications which fall outside of the specifications Schaeffler Customer Service must be contacted if the application falls outside of the specifications in Diagram 1 Schaeffler Group Industrial BA11 9 Mounting and assembly Wall mounting the drive Attention 3 hexagonal head screws M6X25 for wall mounting 2 hexagonal head screws M6X16 for lubricator and holder maximum torque 3 Nm Figure 6 Wall mounting the drive FAG Motion Guard CONCEPT6 CONTROL Procedure for cases where direct fixing at the lubrication point is not possible Screw the holder and drive to a carrier assembly on the machine In the event of a metallic base material use a minimum of three hexagon head screws M6 X25 hole pattern for the three fixing screws in accordance with Figure 6 and the attached hole template The lubrication points and the entire lubricant feed line must be pre greased using the same lubricant as is contained in the LC unit lubricant cartridges for manual grease guns are available as accessories page 25 Connect the lubricant feed line G g external or G internal to the drives outlet and lay to the lubrication point If the thread does not match the connecting thread at the lubrication
8. FAG FAG Motion Guard CONCEPT6 CONTROL Automatic single point and multiple point lubrication system User manual SCHAEFFLER GROUP INDUSTRIAL Features Safety guidelines Technical data Mounting and assembly Display and controls Pulse operation Initial operation and handling Display settings and contents Changing the LC unit Error messages and troubleshooting Accessories and service EU Declaration of Conformity Quick guide to function and operation FAG Motion Guard CONCEPT6 CONTROL Page Application neoini A cesses sseievecedevasegecnas 3 Scope OF delively s cesscconsscecsioscncosnsessvsacocnscansesdusteonscoskenssacecvarecots 4 Legal requirements liability sesseeseseesesseessseessssesssseessseeessse 5 Responsible personS sssssisseseiiessesisssesrsesssssesrcsrsestssssoieseessesiss 5 PriNGiPlOS R E E E E ES 5 Key datami i E E a A E 6 Designit he e e e E a OR 7 FUNIGEI OM EE A E A E AEE 7 Operating condition Sreser itens 8 Wall mounting the drive ee eeesecccesseeeeeesseeeeesseeeeeseeeeeeeeees 10 Assembling the lubricator esssseessseessseesssseesssresssresssseesssreessee 11 FunctiomdisplayS eisses fea cecusceacapdiecess 13 Men control KeyS ccssccsestsessesossccsssessesersesscseseseenerceeonateoenee 14 EE AE T A T A OEE E E 14 Ope ratioN erediens esei na ei ai 16 Deactiv tio Menieg n e a E 17 Low temperature deactivation eesssssessesesereeerssesseesserseersesssees
9. TRIBUTOR The error messages are acknowledged and removed by pressing the SELECT key Due to a low signal from the lubricator the connected controller recognises that there is a malfunction For any malfunction display via the controller the cause must be determined directly via the display on the drive For each error message shown on the display the red LED will also flash Localise and eliminate possible defect sources using the table Reading on the display Defect Possible cause Remedy E1 Lubricator has been deactivated Excessive motor current outlet is blocked Remove blockage acknowledge defect by holding down the SELECT key for a long period E4 Lubricator has been deactivated Drive mechanism defective Replace drive LC System is not detecting an LC unit LC unit missing Fit new LC unit Schaeffler Customer Service will provide assistance if a problem occurs which is not included in the overview 24 BA 11 Schaeffler Group Industrial Accessories and service Replacement parts Figure 20 Replacement parts Due to the high pressure of up to 25 bar only original replacement parts should be used This applies in particular to lubricant feed lines All FAG replacement parts comply with technical requirements 0000AECO Designation
10. and pump 3 MODE SAVE key configuration menu and settings Red LED additional malfunction display LC unit lubricant cartridge Cover with bayonet catch Type of LC unit with lubricant volume in cm Type of lubricant and filling date Display of operating modes GO SELECT key for settings Green LED function display Distributor connector for FAG C6 MP DISTRIBUTOR 3 Connector for lubrication point or lubricant feed line G external or G g internal Figure 22 Lubricator OOOOAEC4 28 BA11 Schaeffler Group Industrial Teeth for positioning the LC unit Contact bridge no function Drive catch for spindle drive Figure 23 Underside of the drive QOOOAEC6 Brown not assigned White fault Blue earth Voltage 15 V to 30 V DC Figure 24 Connection cable for the machine controller OQOOOAEC8 Installing and replacing the Install the lubricators drive directly at the lubrication point using lubricant cartridge the enclosed holder LC unit The lubricant feed line must not exceed 5 m in length Remove the cover disk from the LC unit and place the LC unit in the cover Push the LC unit into the cover until grease escapes from the outlet opening Position the cover with LC unit on the drive the catch must lock into place and the teeth of the LC unit and the drive must engage with each other Rotate the cover in a
11. ctive negative logic Blue earth Black live 15 V DC to 30 V DC Figure 10 Pin assignment of plug on connection cable Attention FAG Motion Guard CONCEPT6 CONTROL Connect and properly isolate the four cords of the connection cable to the machine controller for example PLC Pay attention to the assignment and numbering of the pins on the plug of the lubricator see Figure 10 Insert the plug of the connection cable and screw onto the jack socket of the lubricator 0000AEAC Make connections precisely in accordance with the user manual An incorrect connection can lead to destruction of the electronics Sparking and fire risk due to short circuit Do not work on live parts of the electrical device Protect live parts of the electrical device in accordance with the voltage frequency and type of application by means of isolation position and arrangement 12 BA11 Schaeffler Group Industrial Display and controls The operating condition of the lubricator can be determined from the green and red LEDs and from the display on the control unit see Figure 11 The settings for the lubricator can be performed using the keys and and monitored on the display Error messages generated when there is excessive pressure in the lubricant feed line for example are also displayed LC display Red LED SELECT key FAG C6 MP DISTRIBUTOR connector for up to 6 lubrication points G
12. dure for replacing the LC unit Work steps Rotate the cover on the drive in an anti clockwise direction and remove Remove the LC unit the reading LC will appear on the display and the red LED will flash Remove the cover disk from the new LC unit Figure 7 page 11 Push the LC unit into the cover until the lubricant works its way out of the outlet Figure 8 page 11 Fit the LC unit rotate until the catch locks into place and the teeth of the LC unit and the drive engage with each other The lubricators control system automatically detects the new LC unit appears in the display if the device was previously deactivated or 99 Vol if the device was activated prior to the changeover If the lubricator was activated it will continue to work with the previous running time setting If this not the case start again by applying the supply voltage Where necessary change the configuration of the lubricator page 18 Schaeffler Group Industrial BA11 23 Error messages and troubleshooting Error message due to machine controller Troubleshooting FAG Motion Guard CONCEPT6 CONTROL Any function defects are detected by the electronic control system and shown on the display During a defect display the system will shut down until the defect has been eliminated and the error message has been acknowledged Exception Displays F1 to F6 for connected distributor see user manual for FAG C6 MP DIS
13. e cannot be calculated since the value for the set dispensing time is not present In this case calculation is carried out using the information on the display and the machine controller Schaeffler Group Industrial BA11 21 FAG Motion Guard CONCEPT6 CONTROL Changing the LC unit The simultaneous flashing of the red and green LED combined with the empty level reading on the display Figure 18 indicate that the empty LC unit must be replaced immediately The connected machine controller receives a low signal Attention The LC unit must not be opened or refilled under any circumstances Only new completely filled FAG LC units should be used Protect the drive system and control circuit board against moisture The unit should only be changed in dry conditions When changing the LC unit for a different size the appropriate cover should be used If the setting on the display does not correspond to the size of the fitted LC unit this will lead to incorrect dispensing quantities and displays Dispose of old parts in accordance with the applicable regulations Figure 18 Changing the LC unit Display 00 Vol OOOOAEBC Setting the volume The volume of the LC unit is selected in the configuration menu page 18 by using the two control keys on the drive Two settings are possible Figure 19 Figure 19 LC unit with volume of 250 cm or 500 cm OOOOAEBE 22 BA11 Schaeffler Group Industrial Proce
14. haeffler KG Postfach 1260 97419 Schweinfurt Germany Georg Schafer Strafe 30 97421 Schweinfurt Germany Service Hotline Phone 49 2407 9149 99 Fax 49 2407 9149 59 E mail support fis services de Internet www fis services de Every care has been taken to ensure the correctness of the information contained in this publication but no liability can be accepted for any errors or omissions We reserve the right to make technical changes Schaeffler KG 2009 May This publication or parts thereof may not be reproduced without our permission BA 11 GB D
15. ill appear on the display Further information is contained in the defect table on page 24 Deactivate the supply voltage the remaining volume display Figure 14 page 16 is extinguished and is replaced by the display All lubricator settings remain stored so that upon reactivation the program can continue from the point at which it was stopped The fault output delivers a low signal system not running to the controller Schaeffler Group Industrial BA11 17 FAG Motion Guard CONCEPT6 CONTROL Display settings and contents The configuration menu should be worked through from top to bottom and from left to right and corresponds to the process fora deactivated lubricator Configuration is also possible in an activated state Ka RS te RS O We RS O te 5S fe Ra O te RS te RS O fe S fe RS Delivered condition of fitted LC unit Time setting and PIN reset display PIN entry first digit PIN entry second digit Select volume of the LC unit Set months weeks or days Changing over to days or weeks Set outlets with distributor only Outlet 1 activated amp Outlet 2 activated Change PIN first digit for initial configuration or following PIN reset only Change PIN second digit for initial configuration or following PIN reset only 3 Configuration complete AA We Ra O
16. imetres cm3 100 h for 100 operating hours The dispensing time can then be calculated using the table Average dispensing quantity in cm given in each case for 100 operating hours for the respective LC unit 5 Setting parameter Setting mode Dispensing time LC250 250 cm LC500 500 cm Days Weeks Months Days Weeks Months 1 1041 7 148 8 34 3 2083 3 297 6 68 5 2 520 8 74 4 17 1 1041 7 148 8 34 3 3 347 2 49 6 11 4 694 4 99 2 22 8 4 260 4 37 2 8 6 520 8 74 4 17 1 5 208 3 29 8 6 9 416 7 59 5 13 7 6 173 6 24 8 Spi 347 2 49 6 11 4 7 148 8 21 3 4 9 297 6 42 5 9 8 8 130 2 18 6 4 3 260 4 37 2 8 6 9 115 7 16 5 3 8 28175 Spi 7 6 10 104 2 14 9 3 4 208 3 29 8 6 9 11 94 7 13 5 Spal 189 4 27 1 6 2 12 86 8 12 4 2 9 173 6 24 8 5 7 13 80 1 11 4 2 6 160 3 22 9 53 14 74 4 10 6 2 4 148 8 21 3 4 9 15 69 4 9 9 23 138 9 19 8 4 6 16 65 1 9 3 2 1 130 2 18 6 4 3 17 61 3 8 8 2 0 1a S 4 0 18 57 9 8 3 1 9 wis 16 5 3 8 19 54 8 7 8 1 8 109 6 15 7 3 6 20 52 1 7 4 TA 104 2 14 9 3 4 21 49 6 Tah 1 6 99 2 14 2 33 22 47 3 6 8 1 6 94 7 13 5 3 1 23 45 3 6 5 1 5 90 6 12 9 3 0 24 43 4 6 2 1 4 86 8 12 4 2 8 25 a 8353 26 4051 80 1 27 38 6 TURA 28 SA 74 4 29 3579S 71 8 30 3457 69 4
17. machinery Basic concepts general principles for design Part 1 Basic terminology and methodology EN ISO 12100 2 2003 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN 60204 1 1998 Electrical equipment of machines Schaeffler KG F IS FAG Industrial Services nous Georg Schafer Str 30 97421 Schweinfurt AV A Cw ia flod SL Armin Kempkes Michael General Manager F IS Product Manager F IS Lubrication Products Date Schweinfurt 31 01 2008 This declaration certifies conformity with the stated directives but does not represent a guarantee of characteristics The safety guidelines in the user manual must be observed Schaeffler KG o Georg Schafer Stra e 30 D 97421 Schweinfurt e Tel 49 2407 9149 99 0001410E Schaeffler Group Industrial BA11 27 FAG Motion Guard CONCEPT6 CONTROL Quick guide to function This brief overview contains some important guidelines on and operation how to set the lubricator and how to operate it rapidly and easily It is not a substitute for the detailed user manual Attention Itis imperative that the safety guidelines and extensive information in the detailed user manual be observed This brief overview only applies to the lubricator FAG Motion Guard CONCEPT6 CONTROL in combination with lubricant cartridges LC250 or LC500 Plug for the connection cable to the controller Drive including electronic system motor
18. o 0 C the lubricator reactivates and the ice crystal symbol flashes 20 BA11 Schaeffler Group Industrial Calculating the remaining running time Attention Remaining running time Calculation example for remaining running time Example All dispensing processes which have accumulated during deactivation with the exception of special dispensing processes are made good whereby up to two additional dispensing processes are performed for each planned dispensing process The remaining running time must be recalculated and recorded following each special dispensing process and deactivation SZ RV 100 Riz Definitions SZ Set dispensing time of the lubricator days weeks months RV Displayed remaining volume Vol Riz Remaining running time days weeks months dependent on SZ The lubrication point requires a dispensing quantity of 4 3 cm of grease after every 100 hours The lubricator and LC250 250 cm are set to a dispensing time of eight months as prescribed After two months at a remaining volume of 75 operation is interrupted the equipment and consequently the lubricator remain deactivated for six weeks Once the equipment has been reactivated when should the LC unit be replaced _SZ RV_ 8 75 600_ 100 100 100 6 Riz According to the formula the changeover should be made after six months If the lubricator is configured for pulse operation the remaining running tim
19. oller Apply the supply voltage the lubricator is ready for operation Set the volume of the LC unit the dispensing time the outlets for any connected C6 MP DISTRIBUTOR and the PIN using the keys on the display Alternatively configure the lubricator for pulse operation Operation Activate the supply voltage The reading Figure 14 on the display is replaced with the remaining volume reading for example 99 VOL for a new LC unit The green LED flashes and the fault output supplies a high signal system running to the connected controller Prior to applying the voltage After applying the voltage Figure 14 Readings upon activation 0000AEB4 Then perform a one off special dispensing process The starting up of the drive motor and the illumination of the green LED indicate that the dispensing process has begun The remaining volume of the LC unit appears on the display 16 BA11 Schaeffler Group Industrial During operation Special dispensing processes Machinery downtime Malfunctions Deactivation Check regularly Seal integrity of the lubricator the feed lines and the connections Lubricant fill level Correct position and finger tight screw mounting of all components Calculate the modified dispensing time and incorporate this into the remaining running time of the lubricator and into the lubrication and maintenance plan If the controller is showing a malfunction the reason w
20. ontroller With the exception of the LC unit all of the components can be reused several times E 000155B5 The cable is suitable for use in chain link trunking the minimum bending radius is 60 mm When the lubricator is continuously connected to the power grid it dispenses an adjustable quantity in a defined time interval The lubricant is transported from the LC unit into the drive unit by a spindle driven piston The pump in the drive unit transports the lubricant to the lubrication point at a pressure up to a maximum of 25 bar The size of the LC unit and the dispensing time can be configured in the drive unit Schaeffler Group Industrial BA11 7 Operating conditions Operating temperature Ambient conditions Storage Cover disk Plug Drive Figure 5 Drive unit Attention FAG Motion Guard CONCEPT6 CONTROL A uniform dispensing pattern and the build up of pressure to a maximum of 25 bar can only be ensured in the temperature range from 20 C to 60 C see Diagram 1 page 9 If the individual components are fitted together correctly the lubricators are resistant to dust and spray water However the sealing rings and plastics may be attacked by ambient media Lubricators must only be stored in interior rooms that are dry dust free and protected against sunlight at a storage temperature of 15 C to 25 C Under no circumstances should the c
21. ould be checked immediately for any damage during transit The carrier should be informed of any damage without delay and the damage should be photographed if necessary Attention The LC unit with the suitable grease must be ordered separately Figure 2 LC unit available in two sizes 00014E7F 4 BA11 Schaeffler Group Industrial Legal requirements Liability Attention Safety guidelines Responsible persons Operator Attention Qualified personnel Principles Attention The information data and guidelines given in the user manual were current at the time of editorial approval The data illustrations and descriptions cannot be used as grounds for any claims relating to lubricators that have already been delivered Schaeffler KG accepts no liability for any damage or operational malfunctions that occur as a result of improper use or unauthorised changes to the drive unit or LC unit This also applies to incorrect work on or with the lubricator errors in use or adjustment or incorrect variation sizes of the lubricator ora failure to observe the user manual The operator is the natural or juristic person that uses the lubricator or on whose instruction the lubricator is used The operator or his safety co ordinator are responsible for compliance with all relevant specifications guidelines and regulations All work on and with the lubricator may only be carried out by qualified personnel Persons tha
22. over disk and the stopper be removed from the drive permanently Figure 5 as this will run down the internal back up battery The cover disk and the plug may only be removed immediately prior to initial operation 0000AF0A The LC unit can be stored for up to two years the lubricant fill date should be taken as the controlling factor All other components should be replaced after a maximum of two years Do not store the drive and cover disk separately 8 BA 11 Schaeffler Group Industrial Specifications Range of application standard grease Range of application low temperature grease Impermissible outside of the specifications Diagram 1 Relationship between hose length and operating temperature Example Attention 00014E87 Hose length between 0 m and 5 m inside diameter 5 mm operating temperature between 20 C and 60 C based on standard greases at Schaeffler KG Examples of calculated values from Diagram 1 The operating temperature is 5 C Maximum hose lengths Working across to the right from the 5 C mark gives a maximum hose length of 3 m for standard grease and a maximum hose length of 5 m for low temperature grease Hose feed line length 4 m Maximum operating temperatures Working upwards from the 4 m mark gives a maximum of 10 C for standard grease and a maximum of 5 C for low temperature grease From this it is also visible
23. point use an appropriate reducer Length of the lubricant feed line see Diagram 1 page 9 Unwanted leakages can only be prevented by fitting connections and lubricant feed lines correctly and securely ey R z cial To i 143 45 0000AEA4 10 BA 11 Schaeffler Group Industrial Assembling the lubricator Insert the LC unit into the cover and remove the sealing cap Figure 7 Cover LC unit Sealing cap Figure 7 Assembling the LC unit 0000AEA6 Push the LC unit into the cover until the grease escapes Figure 8 Outlet opening Figure 8 Preparing the LC unit 0000AEA8 Position the LC unit and cover on the drive so that the catch locks into place and the teeth engage with each other Rotate the cover in a clockwise direction until the bayonet catch locks into place see Figure 9 Cover with LC unit Drive Connection cable for the machine controller Figure 9 Connecting the drive and LC unit 0000AEAA Attention The LC unit must be connected to the drive immediately after removing the cover disk and the sealing cap Schaeffler Group Industrial BA 11 11 Designation of the connection cable Brown not assigned White fault low a
24. rature deactivation Attention Flashing ice crystal indicates 0 C to 19 C shown here with 89 Vol as an example Figure 17 Low temperature deactivation function Attention FAG Motion Guard CONCEPT6 CONTROL The special dispensing process can only take place at a temperature of more than 0 C ice crystal Figure 17 is not visible if the lubricator is not dispensing at the exact same time There is a minimum period of 30 seconds between two special dispensing processes Each time both keys are held down fora long period Figure 16 during this time is registered and leads to further special dispensing processes A maximum of 5 special dispensing processes are recorded by the system The remaining running time which has been shortened as a result of the dispensed lubricant quantity must be included in the lubrication and maintenance plan 0000AEB8 The permissible temperature range of 0 C to 19 C is indicated by a flashing ice crystal symbol Figure 17 Special dispensing processes cannot be performed within this temperature range 0000AEBA If the temperature drops to 20 C or less the lubricator shuts down The ice crystal symbol appears permanently the remaining quantity in vol is still displayed No further lubricant is dispensed from this point onwards Damage may occur if appropriate measures are not taken If the temperature rises back to 19 C or higher t
25. reen LED MODE SAVE key Figure 11 Display and control keys on the drive OQOOOAEAE Function displays Display The display cannot be deactivated irrespective of the mains voltage After connection to mains voltage the settings operating conditions and error messages relating to the lubricator are shown on the display Figure 11 During defect free operation the display shows the remaining volume of the fitted LC unit in percent volume vol LED signals The LEDs on the drive Figure 11 and are interpreted as follows LED lit Signal Description Green Flashing every 10 seconds System running Red Flashing every 3 seconds Error or malfunction Green and red Flashing every 3 seconds Replace LC unit immediately Green Continuous Motor running dispensing operation Connection to controller The controller on your machine only allows an indication as to whether the lubricator is operating or is in malfunction mode The controller receives a high signal during operation and a low signal in a malfunction Schaeffler Group Industrial BA11 13 FAG Motion Guard CONCEPT6 CONTROL Menu control keys There are two keys on the control unit Figure 11 and page 13 for setting and menu navigation The key MODE SAVE accesses the configuration menu changes the mode and saves the modified settings for further operation The key SELECT is used to increase the di
26. ses 20 Calculating the remaining running time essessssssssssessssesssressssses 21 sa EEE E E E EN E EEE EE E E 22 EE ERTE T E A A EE 24 EITE AT T A O O T 25 OEA TEER T E E A O EE ET 27 EE AAE E E A OOE E A 28 2 BA11 Schaeffler Group Industrial Features Attention Application Attention FAG Motion Guard CONCEPT6 CONTROL This user manual describes how to work safely on and with the automatic lubricator FAG Motion Guard CONCEPT6 CONTROL The safety guidelines must be observed Any persons working on and with the lubricator must have the user manual available for their work and must observe the relevant information and guidelines The user manual must always be complete and in a fully legible condition The relevant disposal guidelines must be observed From this point onward the FAG Motion Guard CONCEPT6 CONTROL is referred to as the lubricator and the lubricant cartridge as the LC unit The lubricator is clearly identified by a sticker on the drive unit and the LC unit It is intended for machinery and plant where lubrication is to be carried out continuously over a precalculated period during running and feedback to the machine is required It supplies the lubrication point with grease at a pressure up to max 25 bar substantially constantly precisely and irrespective of temperature and can also be activated and deactivated under machine control Characteristic areas of application include the lubrica
27. spensing time in days or weeks or months by one calendar unit per keystroke to change the LC unit to configure the outlets and to set the PIN Short Selection Short Change values Long gt 4 s Switch to new mode store set values Long gt 4 s back to previous mode delete last change Figure 12 Functions of control keys short or long keystroke OOOOAEAF Pulse operation The dispensing process can also be initiated by the connected machine controller The lubricator must first be set to pulse operation in accordance with the configuration menu page 18 In setting mode a value in days must be selected Figure 13 Figure 13 Setting mode Days for pulse operation 0000AEB2 The supply voltage via the controller must be activated for at least 1 minute and then deactivated for at least 20 seconds Each time the machine starts operation the lubricator now delivers 0 5 cm lubricant to the lubrication point If a distributor FAG C6 MP DISTRIBUTOR is installed the supply voltage must remain activated for at least 14 minutes and must then be deactivated for at least 20 seconds 14 BA11 Schaeffler Group Industrial Calculation of the dispensing time no pulse operation The dispensing time is set at six months by the factory The dispensing time for the lubrication point is based on the information provided by the equipment manufacturer for the lubrication quantity required in cubic cent
28. ssing of the keys left left right right left in the INTRO info menu returns the personal PIN to its delivered state of OO If the time display goes out briefly the reset has been successful All other settings remain unchanged If the settings in the currently displayed configuration section LC time outlets PIN are not to be adopted the SELECT key must be held down until the symbol for OFF or the remaining volume in the LC unit VOL appears All other settings and any changes already adopted remain unaffected If during a period of 180 seconds no key is activated ina configuration section the control system automatically reverts to the previously set mode ON or OFF without adopting the changes All previously implemented settings and changes already adopted remain unaffected The option exists to carry out a special dispensing process in order to supply a lubrication point with additional lubricant The special dispensing process can only be carried out while the supply voltage of the lubrication system is activated display of remaining volume by simultaneously holding down both keys for a long period Figure 16 page 20 Schaeffler Group Industrial BA11 19 Special dispensing process Activated lubricator To carry out the special dispensing process hold down both keys simultaneously Figure 16 Special dispensing process Attention Low tempe
29. t are authorised by the person responsible for safety of the plant on the basis of their experience and knowledge to carry out the activities required in the specific case The lubricator must be filled with the correct grease and adjusted such that when it is correctly adjusted and mounted and used as specified it functions without defects and does not cause any hazards This also applies to the interaction with the complete plant and the points to be lubricated Material damage that could arise due to failure of the lubricator must be prevented by suitable measures All retrofitting modification and conversion of the lubricator is prohibited While working on machinery and plant the safety guidelines and user manuals of the manufacturers must be observed The LC unit must not be opened or refilled under any circumstances Keep grease away from eyes skin and clothing The safety data sheets for the greases must be observed Only original LC units from Schaeffler KG may be used Schaeffler Group Industrial BA11 5 Technical data Key data Diameter Length Figure 3 Lubricator FAG Motion Guard CONCEPT6 CONTROL Designation CONCEPT6 CONTROL 250 CONCEPT6 CONTROL 500 Volume of LC unit 250 cm 500 cm Length L 210 mm 260 mm Diameter D 92 mm 92 mm Weight when empty approx 1 30 kg approx 1 37 kg Weight when filled with Arcanol MULTITOP approx 1 53 kg approx 1 82 kg
30. tion points on rolling and plain bearings drive and conveyor chains guidance systems open gearboxes and seals The lubricator must only be used for the purposes stated in the order and confirmed by Schaeffler KG and in accordance with the conditions of use settings and variations described in this user manual It must be ensured that the correct power supply and connection to the plant or controller for example a PLC are provided Connection should only be carried out using the original connection cable Connection should only be made by qualified skilled personnel and installation must comply with national standards such as IEC or VDE The lubrication system must only be equipped with connections and pressure resistant feed lines from Schaeffler KG The lubricator must be protected against chemically aggressive ambient media Schaeffler Group Industrial BA11 3 FAG Motion Guard CONCEPT6 CONTROL Scope of delivery Lubricator Figure 1 Figure 1 Delivery scope of lubricator lubricator with holder connection cable with plug cover and user manual gt 000155BO LC unit The lubricator can be used with two LC units of different sizes The volume of the LC unit and the grease fill correspond to the specific order The delivery should be checked as soon as it is received Schaeffler KG accepts no liability for any defects that are the subject of retrospective complaints The packaging and the device sh
31. y as a percentage and the green LED will flash OOOOAECA The two keys are used to configure the volume of the LC unit the dispensing time the outlets and the PIN Hold down MODE SAVE until the set time appears days weeks or months Hold MODE SAVE down again for a long period until the request for entry of the current pin is visible the PIN cannot be changed in this instance the display PIN 00 represents the delivered state Hold MODE SAVE down as often as required for long periods until the respective configuration menu is reached volume of LC unit dispensing time outlets or PIN change Make the required settings within the menu by briefly holding down MODE SAVE or SELECT 30 BA11 Schaeffler Group Industrial Adoption of settings Hold down MODE SAVE until appears on the display Pulse operation viathe Select pulse operation In the configuration menu change the connected controller setting mode Days to the numerical value OO Activate the supply voltage for at least 14 minutes the lubricator will start the first dispensing process with a lubricant quantity of 0 5 cm The minimum deactivation period between two dispensing processes is 20 seconds oo Deactivating the lubricator Deactivate the supply voltage is shown on the display Schaeffler Group Industrial BA11 31 MATNR 033034710 0000 BA 11 GB D 200905 pdf only Sc
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