SKF CS200 User manual

CS200 Curve Sensor Controller

CS200-S3

Operating Manual

Version 3

Contents page 1

Imprint

The operating manual is part of the curve

sensor controller CS200(-S3).

The manual has been edited in conformity with

applicable standards and rules for technical

documentation.

SKF LUBRICATION SYSTEMS GERMANY AG

reserves the right to make changes to adapt to

technical improvement. Reprinting or copying

even of parts of this manual requires the

permission of SKF LUBRICATION SYSTEMS

GERMANY AG.

Editor

Dipl.-Ing. S. Waschki

Contents

Information Concerning the

EC Declaration of Conformity............................ 2

Introduction ....................................................... 3

Notes Concerning the

Operating Manual.............................................. 3

Applications....................................................... 4

Scope of Supply................................................ 4

Safety Instructions............................................. 5

Design and Function ......................................... 6

Function........................................................... 6

Design ............................................................. 6

Installation......................................................... 9

Setup ............................................................... 9

Electrical Connection ...................................... 9

Operation ........................................................ 13

Operating Elements ...................................... 13

Parameter Settings for Time-Controlled

Lubrication..................................................... 14

Parameter Settings for Travelling Distance

Controlled Lubrication .................................. 15

Parameter Settings for Curve-Controlled

Lubrication..................................................... 17

Combining the Operating Modes................. 18

Maintenance.................................................... 20

Failures ........................................................... 20

Service ............................................................ 20

Specifications.................................................. 22

Information Concerning the EC Declaration of Conformity page 2

For the product designated below:

Curve sensor controller

Type CS200(-S3)

we herewith certify that it conforms to the

pertinent safety requirements set forth in the

following Council Directive(s) for the

harmonisation of the laws of the Member

States...

Electromagnetic compatibility 89/336/EEC

Notes

(a) This declaration certifies the conformity with

the directives listed, but does not entail an

express assurance of properties.

(b) The safety instructions in the documentation

accompanying the product must be

observed.

products is not allowed until evidence has

been provided that the machinery, vehicle

or similar item, into which the product is

integrated, conforms to the regulations and

requirements set forth by the applicable

directives.

(d) The operation of the products on non-

standard line voltage as well as non-

adherence to the installation instructions

can affect the EMC properties and electrical

safety.

If required, you can request the declaration of

conformity or manufacturer’s declaration for this

product from our central contact address.

Information Concerning the EC Declaration of Conformity

Introduction page 3

Introduction

The curve sensor controller CS200(-S3) is a

reliable, technically tried and proven product.

The curve sensor controller CS200(-S3) has

been made in conformity with the generally

recognized technical rules and the applicable

safe working practices as well as the rules for

accident prevention. Still hazards may be

involved in its use, which can lead to injury of

operators or other persons or damage to the

machine or other property.

To ensure trouble-free operation and prevent

hazards, we kindly ask you to read the present

manual carefully and observe the notes

contained in it.

Notes Concerning the

Operating Manual

Text marked with this sign alerts to

special hazards or work that must be

performed with caution.

Use the table of contents to locate the desired

information promptly and successfully.

This operating manual is a part of the system,

and it must be passed on to the company

operating the device upon sale of the system.

Applications page 4

Applications

The curve sensor controller CS200(-S3) -

like all other products of SKF Lubrication

Systems Germany AG - must be used

only as intended and in adherence to the

information contained in the

accompanying operating manual.

We expressly emphasize that dangerous

materials of any type, especially

materials which are classified as

dangerous according to EC directive

67/548/EWG article 2, paragraph 2, may

be stored and transported and/or

distributed with SKF central lubrication

systems and components only after

consulting SKF Lubrication Systems

Germany AG and receiving their written

approval.

None of the products manufactured by

SKF are approved for application in

connection with hot gases, liquefied

gases, gases liquefied under pressure,

steams or fluids that will reach a steam

pressure of more than 0.5 bar above the

normal atmospheric pressure at the

maximum admissible temperature.

The curve sensor controller CS200(-S3) is used

to control central lubrication systems for

lubrication of wheel flanges or rail tops.

Other use or use beyond this purpose is

considered unintended. SKF will not accept

liability for damages resulting from such

unintended use.

Scope of Supply

The curve sensor controller CS200(-S3) is

supplied alone or integrated in a wheel flange

lubrication system. The scope of supply

includes:

curve sensor controller CS200(-S3)

an operating manual

Safety Instructions page 5

Safety Instructions

Please observe the following safety instructions

to ensure trouble-free functioning of the

lubrication system and prevent damage.

The curve sensor controller CS200(-S3)

exclusively serves the purpose of

controlling central lubrication systems

employed in rail vehicles. It is not suitable

to take over safety-related functions or to

detect curves in connection with the

inclination technology. It is likewise not

suitable for application in aviation or for

the purpose of navigation in vehicles of

any type or ships.

Use of lubricants or substances other

than those approved of by SKF in

connection with a SKF central lubrication

system is prohibited.

The system must be disconnected from

the compressed air supply and electric

voltage and depressurized before

undertaking any work on it, e.g. cleaning,

refilling with lubricant, etc.

Do not spray people or animals with

lubricants.

The general rules and safety regulations for

work with compressed air-operated machines,

devices and systems must be observed.

Use the units only in technically perfect

condition for the intended use. Be aware of

hazards and observe the operating manual.

Especially errors that may influence safety must

be resolved immediately.

The safety mechanisms must not be damaged,

dismantled, or in any way made inoperable, nor

must they be replaced by parts which have not

been expressly approved by SKF.

In case of failure, disconnect the unit from the

compressed air supply as soon as possible.

The electrical connection and all interventions

such as repairs, component replacement, etc.

may be carried out only by properly qualified

and instructed personnel.

If devices are improperly connected,

substantial material and personal

damage may be the consequence.

Unauthorised alteration of the device and use of

unapproved spare parts and auxiliaries are not

allowed.

Worn-out systems must be made inoperable

and disposed of properly.

Design and Function page 6

Design and Function

Function

The curve sensor controller CS200(-S3) is used

to control central lubrication systems for

lubrication of wheel flanges or rail tops. The

device controls two spraying nozzles. Control

modes are curve sensor, time or travelling

distance control.

The CS200-S3 is a special version of the curve

sensor controller CS200 and especially meant

for lubrication systems in which all spraying

nozzles in travelling direction are controlled by

only one solenoid valve.

In the time-controlled lubrication mode a

lubrication cycle is triggered after a set pause

time, regardless of the distance travelled.

For travelling distance controlled lubrication the

device features a pulse input allowing it to

receive signals that are proportional to the

distance travelled. A lubrication cycle will be

triggered as soon as a set number of pulses has

been received.

For curve sensor controlled lubrication you can

determine whether the wheel flanges are to be

lubricated on both sides or only on the wheels

lying on the outside of the curve in the direction

of motion.

Additionally, lubrication may pulse operated

while travelling through a curve.

Curves are detected by an integrated sensor

with adjustable sensitivity. Curve controlled

lubrication can be combined with either time or

travelling distance controlled lubrication.

The parameters for the different operating

modes are set at an 8-position DIP switch.

Design

Figure 1 shows the open curve controller

CS200(-S3).

You can see the electrical supply connector (1),

a rotary position switch (2) for sensitivity

adjustment of the curve sensor, the 8-pole DIP-

switch (3) for programming of the unit, a

hardware reset button (4), a push-button (5)

triggering a lubrication and taking over the

parameters set with the selector switches (2 or

3), a cable union M20x1.5 (6) as well as diverse

LEDs (see Figure 2). The protective earth

conductor terminal is identified as position

number (7).

Design and Function page 7

Figure 1. Operating and connecting elements

of CS200 (-S3)

1 Electrical connector

2 Rotary position switch for sensitivity

adjustment of curve sensor

3 DIP-switch for system configuration

4 Hardware reset button

5 DK push-button for manual operation

and takeover of parameters

6 Cable union M20x1.5

7 Protective earth conductor terminal

Design and Function page 8

Figure 2. Overview of LEDs

8 Operating voltage LED, green

9 Valve output 2 (A2), yellow

10 Valve output 1 (A1), yellow

11 Release input (FG), green

12 Direction of motion input (VR), green

13 Pulse input (P), green

14 TXD output (TXD), red

15 RXD input (RXD), green

16 Signal LED 1 (SR), red

17 μC error LED, red

18 Signal LED 2 (SY), yellow

19 Pulse frequency dependent release,

green

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