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Page 1 Next Chapter
Manufacturer's Declaration in the sense of It is hereby confirmed for the product designated This declaration is made on behalf of the
the EC Machinery Directive 98/37/EEC hereinafter: manufacturer/importer
Piston pump with reservoir
We hereby declare that the piston pumps with type KFA10 Willy Vogel Aktiengesellschaft
reservoir of type Motzener Straße 35/37, 12277 Berlin
that it conforms to the essential safety requirements Postfach 480149, 12251 Berlin
KFA and KFAS specified in the directive(s) of the Council for
are designed for incorporation into a machine / for harmonizing the legal regulations of the Member by the members of the managing board
assembly with other machines to form a machine. States ...
Their commissioning shall be prohibited until it is
established that the machine into which this part Electromagnetic Compatibility
has been installed or with which this part is to be 89/336/EEC,
assembled conforms to the provisions of the EC amended by 92/31/EEC, 93/68/EEC
Directive 98 / 37 EC. 91/263/EEC and 93/97/EEC
Heinz Gaub Manfred Neubert
Conformity has been established through the
WILLY VOGEL application of the following (harmonized) European
Aktiengesellschaft standards:
Berlin, 26 February 2001
EN 50081-1
EN 50082-2
EC Declaration of Conformity
It is hereby confirmed for the product designated This declaration is made on behalf of the • This declaration certifies compliance with the
hereinafter: manufacturer/importer specified directives, it may not be construed as
Piston pump with reservoir a warranty of any qualities, however.
type KFA1, KFAS1 Willy Vogel Aktiengesellschaft
Motzener Straße 35/37, 12277 Berlin • The safety hints contained in the documentation
that it conforms to the essential safety requirements Postfach 480149, 12251 Berlin supplied along with the item shall be observed.
specified in the directive(s) of the Council for
harmonizing the legal regulations of the Member by the members of the managing board • The products covered by the declaration may
States ... not be commissioned unless it has been ensured
that the machine, the vehicle or the like into
Electromagnetic Compatibility which the product has been installed conforms
89/336/EEC, to the provisions and requirements of the
amended by 92/31/EEC, 93/68/EEC applicable directives.
91/263/EEC and 93/97/EEC
Heinz Gaub Manfred Neubert • Any use of the products with a mains voltage
Conformity has been established through the other than that required by the applicable stan-
application of the following (harmonized) European dards as well as non-observance of installation
standards with respect to the directives: hints may affect the EMC characteristics and
Berlin, 26 February 2001 electrical safety.
EN 50081-1
EN 50082-2
Installation
Page 8
Pressure
relief valve
Page 12
Filling
Page 12
Pump elements
Page 10
Page 6 Next Chapter
1. Safety hints
General units. These persons are familiar with the applicable Installation work
standards, rules, accident prevention regulations
The components are designed and manufactured Wen installing the products in vehicles and
and operating conditions on account of their training,
in conformity with the generally accepted machines, the local accident prevention regulations
experience and the instructions received. They are
engineering standards as well as applicable as well as the applicable operating and
entitled to carry out the activities required in a
industrial safety and accident prevention maintenance instructions shall always be observed.
given case and will be able to recognize and avoid
regulations. Though constructed to meet all relevant
possibly existing dangers.
safety requirements, their use may still entail Danger caused by electrical current
DIN VDE 0105 or IEC 364 contains the definitions
dangers leading to personal injury of the user or
for specialists and the prohibition to use unqualified The units may be connected to the power supply
third parties or damage to property. Therefore, the
personnel. exclusively by appropriately trained qualified
components shall only be used when they are in
personnel in conformity with the local connection
a technically perfect condition, the operating Disclaimer of liability conditions and regulations (e.g. DIN, VDE)!
instructions having to be duly observed. Any faults,
Improperly connected equipment may lead to
in particular faults which may affect safety, shall Vogel cannot be held liable for any damage:
serious personal injury and damage to property!
be rectified without delay.
• caused by lack of lubricant
Danger caused by system pressure
Use in conformity with intended purpose • caused by contaminated or unsuited lubricants
The units may be pressurized. Therefore, they
The Vogel pump units type KFA and KFAS are • caused by the installation of components or
must be made pressure-less before any extension
designed for the supply of centralized lubrication spare parts other than genuine Vogel
work, modifications or repairs are carried out.
systems of vehicles, plants and machines. They components or spare parts, respectively
are capable of delivering greases up to NLGI
• caused by any use which is not in conformity
grade 2.
with the intended purpose
Any use beyond this scope shall be deemed as
being not in conformity with the intended purpose. • caused by inappropriate installation and filling
• caused by wrong electrical connection
Approved personne l
• caused by erroneous programming
The components described in this manual may be
installed, operated, maintained and repaired only • caused by improper reactions to malfunctioning
by qualified personnel.
• caused by non-observance of the operating
Qualified personnel means persons trained,
instructions
assigned and instructed by the operator of the
Page 7 Contents Chapter
2. Installation
General Mount the KFA and KFAS pump units to the vehicle When drilling, pay attention to the
or machine with the 3 supplied M8 bolts, washers following possible hazards:
The pump units of the KFA and KFAS series are
and self-locking nuts.
designed for use in centralized lubrication systems
Tightening torque: 16 Nm. • Existing supply lines
of vehicles, machines and plants. They are capable
The unit should be mounted at a position which is
of delivering greases up to NLGI grade 2. • Other units
protected to the greatest possible extent. Where
The pump units differ in the way they can be
holes have to be drilled for installation, position • Moving parts
electrically connected as well as in the control and
these holes as shown below. A drilling template is
monitoring of functions. If application specific pump • Heat sources (exhaust etc.)
available under order number 951-130-148.
elements are installed, up to two separate
lubrication circuits can be operated with one unit Mind safety distances as well as local
(see section 2.3). installation and accident prevention regulations.
234
150
The pump units KFA and KFAS are fitted with two All pump elements are provided with an internal
lubricant outlet ports. To each outlet port, a separate thread M14x1.5 for connection to a pressure
pump element for an independent progressive relief valve with tube port for steel tubes 6 mm
feeder circuit can be connected. or 10 mm. 4
Order the pump elements in accordance with your The pump elements are externally marked on the
2
specific lubrication application. spanner surface with grooves.
3
The pump element is fitted only with Available pump elements 1
O-ring 15.4x2.1 (1) without any additional
seal ring. Order No. Output Number
in cm3 /min of grooves
KFA1.U1 2.0 1
1 KFA1.U2 1.5 2 Figure 4 Connection of pump elements and
KFA1.U3 1.0 3 pressure relief valve
Step 1:
Screw out pump element.
If the piston of the pump element gets stuck in the
lubricant present in the strainer ring, remove it with
a suitable tool. Figure 6 Sectional top view of pump casing
1 Fixing thread
2 Guiding groove in strainer ring
3 Cam-disc
4 Return disc
The pressure relief valve is used to protect the The lubricant is filled in via the conical head
entire lubrication system against excessive internal lubrication nipple DIN 71412-AM10x1 with a
pressures. The valve is set to open at a pressure A R standard pressure grease gun.
of 300 bars. If the operating pressure increases
beyond 300 bars due to a blocked progressive
feeder or lubricating point, the valve opens, and
grease visibly emerges from the valve.
P M14x1.5 4
This allows optical system monitoring.
3
A Connection for tube 6 mm 5
P Connecting thread for pump element
Order No. Tube Opening pressure R Grease emerges here in case of
6
in bars R
161-210-012 ø 6 mm 300 ± 20 bars 2
161-210-016 ø10 mm
1
M14x1,5
5 Lubricant
6 „min“ marking
A Connection for tube 10 mm
Initial filling Visual • Disconnect the main lines from the unit. Operate
the pump until the lubricant emerging from the
Which lubricants may be used with the units may The transparent reservoir enables you to visually
pressure relief valve is free of bubbles.
be seen from the current release list "Schmierstoffe monitor the level. The level should be checked at
Reconnect the main lines.
für Progressivanlagen" regular intervals for safety reasons. The current
at: www.vogelag.com level can be precisely seen from the position of • Disconnect the main line from the main
the follower. distributor. Operate the pump until the emerging
When the unit is filled for the first time, the lubricant lubricant is free of bubbles. Reconnect the
forces the follower upward until the overfill outlet When the level in the reservoir has main line.
opens. As filling continues, the air escapes until dropped below the „min“ marking, bleed
• Disconnect secondary lines from main distributor.
the entire reservoir is filled with lubricant. When the entire system.
Operate the pump until bubble-free lubricant
excess lubricant starts to emerge from the overfill
emerges from all ports of the main distributor.
outlet, stop filling completely. Level switch
Reconnect the secondary lines.
When topping up, take care not to let lubricant
Pump units of the KFA and KFAS series are
emerge from the overfill outlet. Danger of accident • Finally, bleed secondary lines, secondary
available with an automatic level control function
or environmental pollution! distributors, lubricant lines and lubrication points,
(see section 2.2).
and check for proper functioning.
KFAS: When the level drops below the „min“
marking, the sequence of operations is
stopped, and a fault message „FLL“
appears in the display.
KFA: The level signal is output via the
appropriate connector
(see sections 3.2, 4.2, 4.6).
Note !
Pump units with electrical level control are identified
by a „W“ in the order description.
Figure 9 Point at which lubricant emerges
Page 14 Contents Chapter
3.2 KFA1, KFA1-W KFA1 without level monitoring KFA1-W with level monitoring
Cable set Cable set
+ +
KFA1 KFA1-W Q
M M
4 1
- -
WS
- -
2 3
X1 1 2 3 4 X1 1 2 3 4
X1 5) 5)
BN
PK
BN
BK
RD-BK
RD-BK
1) 1)
Figure 10 Circular pin-and-socket connector max.
F 3A F 3A 0,5 A
15 31 15 31 4)
BN
Observe the information and instructions Rated Typical power Pump starting Max.
contained in the operating manual and func- voltage input (load- current back-up fuse4)
tional description of the respective control unit dependent) 2) (ca. 20 ms)
as well as the safety hints (see section 1) !
If the protective conductor connection is not KFA1-M... / KFAS1-M... 24 V DC 1) 0.5 A ca. 1.4 A 3.0 A
established or interrupted, dangerous touch Industrial applications
voltages may occur on the unit ! Duty type S3 20%,
50 min
Supply voltage 24 V DC KFA1-M without level monitoring KFA1-M-W with level monitoring
This unit is provided only with pin-and-socket This unit is provided with the pin-and-socket
Mind voltage values specified on
connector X1. connectors X1 and X2.
nameplate and in section 4.1!
3 KFA1-M-W
1
X1 Electrical connection: Pin-and-socket
connector according to DIN 43650-A.
2
+
X2 Signal output from level switch WS KFA1-M
circular pin-and-socket connector M12x1. M KFA1-M-W
- Q
-
WS
3 X1 1 2 3
1
X1 X2 1 2 3 4
2
4 3
5) 5)
1)
1 2
BK
BN
BU
Connector
WH
F 3A + MIN 5) OK
4 3 X2
X2 Connector 24 V DC, max. 0.5 A
1 2 L+ M (OV, GND)
24 V DC
Supply voltage 24 V DC KFAS1-M These units are provided with the pin-and-socket
connector X1 for the voltage supply and with a
The KFAS1-M unit is provided only with the pin-
Mind voltage values specified on circular pin-and-socket connector M12x1 for con-
and-socket connector X1.
nameplate and in section 4.1 ! nection of an external cycle switch (X3).
No internal level monitoring !
No external cycle switch monitoring !
X 1 Electrical connection: Pin-and-socket
connector according to DIN 43650-A. 3
1
KFAS1-M-W
Applies to all KFAS1-M units ! X1
2
1
X1 KFAS1-M-W With internal level monitoring.
Connector
A built-in level monitoring facility is always active.
2
Connector KFAS1-M-Z When the level drops below the „min“ mark, the
KFAS1-M-W-Z 4 3
sequence of operations is stopped, and a fault X3
message appears in the display.
1 2
No external cycle switch monitoring !
X1 1 2 3
Socket
1
1
4
4
2
3
2
3
5 BK black
X3 X3 6 BK black
2 1 2 1
7 VT-GN violet-green
BN
BK
BN
BK
BU
X3
WH
X3 4-pole pin-and-socket connector X1
Socket Socket
ZS
X1-PIN Color code Core color
ZS ZS
1 RD-BK red-black
24 V DC 24 V DC 2 BN brown
3 BK black
3-wire switch 4 PK pink
2-wire switch optionally as break contact element
(WH) or make contact element (BK)
Color coding
1 BN brown
2 WH white
3 BU blue
4 BK black
Page 21 Contents Chapter
4.6 KFA10, KFA10-W KFA10 without level monitoring KFA10-W with level monitoring
Supply voltage This unit is provided only with pin-and-socket This unit is provided with the pin-and-socket con-
115 V or 230 V AC 3 A 50/60 Hz connector X1. nector X1 for voltage supply and, in addition, with
the circular pin-and-socket connector M12x1 (X2)
Mind voltage values specified on for the signals output from the level switch WS.
nameplate and in section 4.1 !
KFA10 3 KFA10-W
1
X1 Electrical connection: Pin-and-socket KFA10-W
2
connector according to DIN 43650-A.
X2 Signal output from level switch WS
Connectorr X1
circular pin-and-socket connector M12x1. M Q
1~
WS
3
1
X1 1 2 3
4 3 X2 1 2 3 4
X1
2
5) 1 2
1)
BN
BU
BK
WH
Connector
X2 + MIN 5) OK
4 3 F 4A Connector
X2 24 V DC, max. 0.5 A
WS Built-in level switch
1 2 L1 N PE Contact position shown: Filled reservoir
115 or 230 V AC
50 / 60 Hz Color coding
Figure 14 Pin-and-socket connectors KFA10-W
X2-PIN Color code Core color
1) External control unit
relay contact „Pump ON“ 1 BN brown
5) PIN without internal connection 2 WH white
3 BU blue
4 BK black
Page 22 Contents Chapter
Pushbuttons
• Turn on display
• Display values and parameters
• Set values and parameters
During normal operation, the display is off. It is t = TIMER The control unit operates as a time- • Part of lubrication cycle
activated by briefly operating one of the two PA = PAUSE controlled contact maker (TIMER) Entered and displayed value
pushbuttons . It is used for displaying and is in the PAUSE mode in hours
current values and preset parameters. In addition,
the display is used for operator prompting during
programming of operating parameters. c = COUNTER The control unit operates as a • Part of lubrication cycle
PA = PAUSE contact counter (COUNTER) • The device counts the pulses
and is in the PAUSE mode from an external contact maker
and compares them with the
preset values
t = TIMER The control unit operates as a time- • CONTACT = time during which
CO = CONTACT controlled contact maker (TIMER) the pump delivers
and is in the pump running mode • Entered and displayed value
(CONTACT) in minutes
Fault: Low Level The minimum level in the reservoir has been • The control unit is in the FAULT mode.
reached • The sequence of operations is stopped.
Fault: Cycle Switch No signal from cycle switch during pump • The control unit is in the FAULT mode.
running time • The sequence of operations is stopped.
Operation Hour Meter The subsequently displayed values are the operating hours of the control unit.
Fault Hour Meter The subsequently displayed values are the fault hours. Time during which the control unit or the
machine has been operated in the FAULT mode.
Block operation Signal from cycle switch missing. Contrary to normal operation, the control unit is still in the monitoring
mode. If the fault continues to exist for 3 pump running periods, a fault message is displayed.
Page 25 Contents Chapter
5.2 Display via light-emitting LED LED lights = display mode LED flashes = programming mode
diodes
Operating voltage is applied to pump Value for PAUSE can be changed
unit and control unit. The system is in
PAUSE
h/lmp
the PAUSE state
A cycle switch is used for monitoring Type of monitoring can be changed or disabled
the system. Monitoring is performed at in the programming mode.
CS the progressive feeder during running The cycle switch is operated by the piston of
of the pump. (CONTACT) the distributor to be monitored.
The pressure switch monitoring function This type of monitoring is not permissible
is not possible in progressive feeder for progressive feeder systems.
PS
systems. COP = CS or COP = OFF
The LED must not light. (see section 7.3)
The operating voltage is applied to the pump unit and control unit. The control unit is
in the operating state FAULT. The fault can be called up via the LED display and
FAULT
displayed as error code after pressing of the pushbutton .
The sequence of operations is stopped.
Page 26 Contents Chapter
• Operating the button during PAUSE will initiate an intermediate lubricating cycle
10 / 11
13 / 14
9 Press for Changes are written to the memory, and the LED indicators
more than 2s extinguish.
Page 30 Contents Chapter
7.3 Changing the system monitoring 7.4 Changing the operating mode
Carry out steps 1 and 2! Carry out steps 1 and 2!
7 New settings are written to the memory, and 7 New settings are written to the memory, and
the LED indicators extinguish. the LED indicators extinguish.
Press for more Press for more
than 2s than 2s
Page 31 Contents Chapter
8. Operating modes
Core color
7
black
2
3
9. Technical data
Max. operating pressure 300 bars Applicable technical standards and directives
Permissible operating temperature DC -25 °C to +75 °C 95/ 54/ EC (Vehicles)
AC 0 to +40 °C 89/336/EEC (Electromagnetic Compatibility)
Number of outlets max. 2 73/23/EEC (Low Voltage Directives)
Output of pump element 2/1.5/1 cm3/min
98/37/EC (Machinery)
Reservoir capacity 1l
Lubricants Greases up to NLGI grade 2 with EP
additives, flow pressure up to max. 700 mbars Observe duty type / duty cycle and
ambient conditions; otherwise there is
Weight the danger of overheating of motor!
Filled lubricant reservoir KFA(S)1 3.7 kg
KFA10 4.8 kg
System of protection according to DIN40050 T9
Commercial vehicle types IP6K9K
Industrial types IP55
10
10. Faults
Check level in reservoir at regular 10.1 Displaying faults
intervals. If the reservoir has been
emptied completely, the entire system Start display mode with one of the two keys
must be bled after topping up.
Operate until fault is displayed.
All fault messages are displayed as a centralized
alarm via the light-emitting diode . When Display Meaning
a fault message is output, the normal sequence
of operations is stopped by the control unit, and Fault Cycle Switch: No signal from cycle switch during pump running time.
the fault concerned is stored and displayed. (see section 10.5 Block operation)
The cause of the fault can be read on the display.
This considerably facilitates the fault diagnosis. Fault Low Level:
This function is available only, if system monitoring Lubricant has dropped below minimum level in reservoir.
is active, however. The further sequence of operations is stopped.
The time for which the control unit and the pump unit
have been operated without lubrication is stored in an
undeletable manner in the EEPROM as fault hours Fh.
Page 36 Contents Chapter
10
Fault time counter Carry out the following maintenance and inspection
works at regular intervals:
The time which elapses since the occurrence of a
fault message up to the time when the fault is
• Check level in reservoir
rectified is added in hours. Releasing a lubrication
• Check the plant components for leakage at
cycle via the DK key causes the fault message to
regular intervals
be cleared. Thereafter, this value is automatically
• Check the bearings visually for a proper
transferred to the fault hour counter.
lubricating condition
• Check electrical cables for damage
Fault hour counter
• Check electrical connections and contacts
In the fault hour counter, all fault times which have
• You can check the basic function of the control
occurred during the entire operating period of the
unit and system components by initiating an
unit are totaled up. After calling up parameter Fh,
intermediate lubrication cycle
you can read out the current reading of the counter
• Check electrical connections in case of fault
in the display mode in two blocks of three digits
messages
each (see section 6).
• Replace defective fuses only by equivalent new
ones
The counter can display a maximum of 99,999.9
hours. The smallest storable interval is
Any works beyond the above-mentioned
0.1 hour = 6 minutes. The memory cannot be
scope shall be performed only by
erased.
approved VOGEL service personnel.
Fill in clean grease only.
10
The control unit responds to a missing signal from A total of three lubrication cycles are
the cycle switch by changing over to the block carried out with interrogation of the cycle
mode. Possible causes: switch.
10
• Suction problems due to air inclusions Dismount pump element, and operate pump via key DK until
in grease grease emerges at housing outlet
Page 39 Contents Chapter
Pressure relief valve on pump opens, and • System pressure exceeds 300 bars, Check system, and carry out repair or modification of system
lubricant emerges e.g., due to clogging of distributor or so that the system pressure at 20 °C will not exceed 200 bars
clogged lubrication point as a maximum
Service in Germany
WILLY VOGEL AG
Technical Sales Office
Nürtinger Straße 46
72622 Nürtingen
(++49) 70 22-5 67 36
(++49) 70 22-5 53 32
Page 41 Next Chapter
Service worldwide
Service worldwide
Service worldwide
LUBTEC s.r.o.
Opolany 162
28907 Libice nad Cidlinou
(++420) 324-67 75 45
(++420) 324-67 71 84
E-mail: lubtec@lubtec.cz
Turkey
HIDROPAK
Hidrolik-Pnomatic Aksam
Sanayi ve Ticaret AS
Perpa Is Merkezi K 11 No. 1620
80270 Okmeydani
(++90) 212-2 21 12 27/ 28/ 29
(++90) 212-2 21 74 88
E-mail: hidropak@superonline.com