- Control voltage: 12 V DC or 24 V DC
- Programmable pause time: 0,9 to 9 h
- Programmable pump runtime: 2 to 20 min
- Suitable for piston pump series KFAS and KFGS
IG502-I electronic control and monitoring unit integrated in KFGS and KFAS pump units
The IG502-I control and monitoring unit is an integral component of KFGS and KFAS pump units. Its functions are specially designed for the control and monitoring of centralized lubrication systems on commercial vehicles (traveling machinery). The control unit can be programmed by the customer to suit the vehicle‘s or machine‘s operating conditions and can be set for the following modes of operation:
- TIMER without monitoring
- TIMER with monitoring
- COUNTER without monitoring
- COUNTER with monitoring
Interval (tPA) in the “TIMER” mode
The interval (pause between two lubrications) in the TIMER mode is determined by a clock cycle generated by the control system and by the value programmed as tPA. It can be set for a value between 0.1 and 99.9 h.
Interval (cPA) in the “COUNTER” mode
The interval (pause between two lubrication routines) in the COUNTER mode is determined by the interval between pulses arriving at input DK (signal change from 0 V to 24 V) and by the value programmed as cPA. It can be set for a value from 1 to 999 pulses. In this mode, terminal DK leading out of the unit is used as a counter input to trigger lubrication after a defined number of pulses. In this case, it is not possible to press an external pushbutton to trigger intermediate lubrication.
Setting the interval and pump running times as well as desired monitoring function
The operations required to set the control unit for the values and functions in line with the vehicles‘ use can be found in the operating instructions included with the pump unit.
(standard “TIMER” function without monitoring)
The lubrication periods are repeated on a cyclical basis at the rate of the selected interval (tPA or cPA). The pump running time during a lubrication routine corresponds to the time in minutes set on the control panel as tCO (contact time).
The intervals as well as the pump running times are executed only when the power is on (terminals 15 and 31 connected to 12 VDC or 24 VDC, depending on the unit). If the power is switched off (interruption of the voltage to terminal 15), the currently running residual time is stored and continued after the power is switched on again.
If the monitoring function CS is programmed (this is only done for centralized lubrication systems with cycle switches), the cycle switch mounted on a progressive feeder is queried for the emittance of a signal while the pump is running. At least one signal change (either ON>OFF or OFF>ON) is expected from the control routine at terminal ZDS in the cable harness in order for a new interval to start at the end of the pump‘s running time and for the sequence of functions to continue normally. If this signal fails to materialize during the preset pump running time (tCO), a monitoring program (block mode) is started at the end of that period. In this program routine the pump unit is additionally switched on at specially defined intervals up to a maximum of two times and the cycle switch is monitored for the emittance of a signal.
When the cycle switch signal arrives at the control unit, the monitoring program is immediately ended and operation with the normal sequence of functions is continued. When the monitoring program elapses, a fault signal is admitted at the end and the functional sequence stopped. No intermediate lubrication can be triggered while the monitoring program is running.
The control system comes with a non-volatile memory (EEPROM), so a constant supply of power is not required for the storage of residual times and fault signals. When the power is switched off (ignition), the current value is stored and is available for the further sequence of functions after the power returns.
Monitoring and fault displays
Function monitoring with cycle switch
Centralized lubrication systems can be monitored with cycle switches. For this to be done, the unit has to be set (programmed) under COP for CS monitoring (cycle switch). The signal emitted by the switch during the lubrication routine is then monitored. If no signal is emitted during both the lubrication routine and the monitoring program automatically started thereafter, a fault signal is emitted at the end of the monitoring program (terminal SL2 is constantly on) and the functional sequence is interrupted. The FCS error code (Fault Cycle Switch) can be invoked by pressing a button on the control panel.