ABB ZSD 2020 User manual

ABB Automation GmbH
Grüner Weg 6 | 61169 Friedberg, Germany
Phone: [phone] | Fax: [phone]
E-Mail: | Internet:
TRANSLATION OF ORIGINAL - en
Overhaul instructions
Keep for future use!
Version: 1.2
ZSD 2020
Central lubrication unit

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
Scope Page 2 of 50
Scope
Assembly: Central lubrication unit dosing unit ZSD 2020 ABB
Product Version: ZSD 2020
Item Number: 3HDA10100097017
Drawing Number: 80003300-013
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
Indexes Page 3 of 50
Indexes
Contents
1 General information........................................................................................................... 6
1.1 Purpose of these instructions......................................................................................6
1.2 Target readership of these instructions.......................................................................6
1.3 Legal Notice / Liability................................................................................................. 7
1.4 Co-Applicable Documents........................................................................................... 7
1.5 Information symbols used in these instructions.......................................................... 8
1.6 Safety Notes................................................................................................................ 9
1.7 Risks in Using the Module........................................................................................ 10
1.8 Safety Measures........................................................................................................12
1.9 Position numbers.......................................................................................................12
2 Tools and accessories.................................................................................................... 13
3 Removing.......................................................................................................................... 14
3.1 Notes..........................................................................................................................14
3.2 Removing of the container........................................................................................ 15
3.3 Removing the filling strainer......................................................................................19
3.4 Removing the oil filter............................................................................................... 22
3.5 Removing the diaphragm pump................................................................................24
3.6 Removing the solenoid valve.................................................................................... 27
3.7 Removing the local control switch............................................................................ 30
4 Cleaning and assembly preparation..............................................................................33
5 Installation.........................................................................................................................34
5.1 Fitting the container...................................................................................................34
5.2 Fitting the filling strainer............................................................................................ 38
5.3 Fitting the oil filter......................................................................................................41
5.4 Fitting the diaphragm pump...................................................................................... 42
5.5 Fitting the solenoid valve.......................................................................................... 45
5.6 Fitting the local control switch...................................................................................48
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
Indexes Page 4 of 50
List of illustrations
Figure 1: Releasing the clamp fasteners.........................................................................15
Figure 2: Removing the container................................................................................... 16
Figure 3: Taking off the lid............................................................................................... 17
Figure 4: Removing the filling strainer.............................................................................18
Figure 5: Removing thumb screws.................................................................................. 19
Figure 6: Taking out the filter unit....................................................................................20
Figure 7: Unscrewing the filling strainer.......................................................................... 21
Figure 8: Unscrewing the oil filter....................................................................................22
Figure 9: Removing the oil filter...................................................................................... 23
Figure 10: Disconnecting hoses........................................................................................ 24
Figure 11: Release screws................................................................................................ 25
Figure 12: Removing the double diaphragm pump........................................................... 26
Figure 13: Removing the solenoid valve........................................................................... 27
Figure 14: Removing solenoid valve mounting screws..................................................... 28
Figure 15: Removing the solenoid valve........................................................................... 29
Figure 16: Removing the local control switch....................................................................30
Figure 17: Removing the switch mounting screws............................................................31
Figure 18: Removing the local control switch....................................................................32
Figure 19: Screwing on the filling strainer.........................................................................34
Figure 20: Fitting the container..........................................................................................35
Figure 21: Fitting the lid..................................................................................................... 36
Figure 22: Closing the clamp fasteners.............................................................................37
Figure 23: Screwing on the filling strainer.........................................................................38
Figure 24: Insert the filter unit........................................................................................... 39
Figure 25: Fastening thumb screws.................................................................................. 40
Figure 26: Screwing on the oil filter...................................................................................41
Figure 27: Fitting the double diaphragm pump................................................................. 42
Figure 28: Fitting screws....................................................................................................43
Figure 29: Fitting tubes...................................................................................................... 44
Figure 30: Fitting the solenoid valve................................................................................. 45
Figure 31: Securing of the solenoid valve.........................................................................46
Figure 32: Connecting hoses and plugs............................................................................47
Figure 33: Positioning the local control switch.................................................................. 48
Figure 34: Screwing on the local control switch................................................................49
Figure 35: Fitting the local control switch..........................................................................50
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
Indexes Page 5 of 50
List of tables
Table 1: Personnel skills requirements............................................................................ 6
Table 2: Personnel and their activities............................................................................. 7
Table 3: Tightening torques............................................................................................ 33
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
General information Page 6 of 50
1 General information
1.1 Purpose of these instructions
These instructions describe the repair of the central lubrication unit.
IMPORTANT
Follow these instructions!
•These instructions must be assessable to everybody that handles this module in
any way.
•The operating company must ensure that these instructions are read and under-
stood by everybody that handles this module in any way.
The components connected to this module are covered in separate instruction manuals.
DOCUMENTS REFERENCE
Observe reference documents!
•Read the instruction manual for the module in its entirety before operating the
equipment for the first time!
•Also note the corresponding chapter of the provided sub-contractor documenta-
tion of purchased parts! If you have any questions please contact our Customer
Service or the manufacturers directly.
1.2 Target readership of these instructions
These instructions must be observed and used by maintenance and repair personnel.
Persons working with the assembly must have been suitably trained by the manufacturer or
plant owner.
The repair personnel must be suitably trained.
Personnel Prerequisites
Briefed personnel
Operating personnel are people who have been instructed by
the plant owner or trained persons to carry out tasks relating to
the operation of the plant. They must provide instruction about
possible dangers arising from incorrect behaviour and about the
required protective equipment and safety measures.
Trained personnel
Has received in-depth subject education and training, is cable
to assess the plant’s safety status and is familiar with the applic-
able accident prevention and health and safety regulations and
with the acknowledged rules of technology.
Table 1: Personnel skills requirements
The table below outlines what work each of these user groups is authorised to perform:
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
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Overhaul instructions
Central lubrication unit
General information Page 7 of 50
Activity Briefed
personnel
Trained
personnel
Operating the plant X X
Perform maintenance and repair work and tooling X
Table 2: Personnel and their activities
1.3 Legal Notice / Liability
The manufacturer assumes warranty and liability claims only under the conditions specified in
the contract and in compliance with the warranty periods.
The warranty expires:
•In the event of errors and damages that can be attributed to the fact that instructions in the
manual have not been observed,
•In the event of complaints that can be attributed to the fact that others then the original
parts specified in the documentation were used when replacing components,
•When changing the module (function, operating parameters) disregarding the conditions
specified in the order and without prior consent of the manufacturer.
The content of the technical documentation has been prepared with the utmost care. However
no liability is assumed for possible errors or incompleteness. This also applies to the content
of the technical documentation of all sub-contractors.
The documentation contains information that is protected by copyright. All rights reserved. This
documentation may not be reproduced without the expressed written permission of the manu-
facturer. It may not be electronically or mechanically reproduced, distributed, modified, surren-
dered to third parties, translated or otherwise used - not even excerpts.
Technical changes and errors are not impossible.
1.4 Co-Applicable Documents
These instructions refer to drawings and parts lists of the
Assembly: ZSD 2020
DOCUMENTS REFERENCE
For further information on the scope of validity of this manual and the modules de-
scribed, see section "Scope".
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
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Central lubrication unit
General information Page 8 of 50
1.5 Information symbols used in these instructions
The entire documentation contains notes about workplace safety that are intended to prevent
injury.
These notes are labelled with the following signs and symbols:
DANGER
This box indicates an immediate danger.
Unless prevented, this situation can lead to severe injury or death.
WARNING
This box indicates a potentially dangerous situation.
Unless prevented, this situation can lead to severe injury or death.
CAUTION
This box indicates a potentially dangerous situation.
Unless prevented, this situation can cause minor injury or material damage.
IMPORTANT
This box indicates a potentially dangerous situation.
Unless avoided, this situation can lead to material or product damage.
NOTE
This box contains important notes that require special attention.
Notes without a specific sequence are given with bullet points. If a specific order is
necessary, these notes are numbered.
DOCUMENTS REFERENCE
This box contains cross-references to associated documents.
References without a specific sequence are given with bullet points. If a specific order
is necessary, these references are numbered.
ENVIRONMENTAL PROTECTION
This box contains information about environment-conscious procedures and
behaviour.
It may indicate environment protection measures.
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
General information Page 9 of 50
1.6 Safety Notes
When working on or with the assembly, observe the following general safety instructions:
1. The safety instructions must be observed at all times to prevent accidents.
2. The regulations and information in the operating instructions and in the user documenta-
tion of third-party products as well as all safety instructions must be observed to ensure
safe and reliable operation of the assembly.
Observing this information helps identify hazards and prevent dangerous situations.
Observing these safety instructions is a precondition for workplace design.
They must be made available to all users before performing any action on the plant
and the plant components and must, in part, be contained in the personnel briefing
and training.
3. The Occupational Safety Provisions and Accident Prevention Regulations of the relevant
country are applicable in which the component is operated.
The operating company of the system is responsible for implementing these provi-
sions.
4. Only trained and instructed expert staff may undertake conversion of the component.
5. For work on the assembly, the personnel has to have access to personal protective
equipment such as protective work wear, safety gloves, helmet and safety goggles.
6. In the event of a fault, the assembly has to be switched off and a fault message has to be
displayed.
Please inform the manufacturer about the fault if the fault cannot be eliminated easily.
If necessary, it has to be ensured that the master switch and the shut-off valves on the
maintenance units are switched off and secured against accidental start before any
work on the assembly is carried out.
Troubleshooting and elimination of faults may only be carried out by trained expert
staff.
7. Persons can be injured severely, even die, due to moving plant parts (e.g. robot) and
components (e.g. gripper).
Working in the cell (protected area) is only allowed with secured lockout bar/padlocks.
All work within the cell must be performed only by trained, briefed specialists.
DANGER
Never override the safety devices! They are intended to protect your life.
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
General information Page 10 of 50
IMPORTANT
The work described here must be carried out only with the plant depressurized and
isolated from mains power.
1.7 Risks in Using the Module
DANGER
Danger through electric current!
Risk of serious or fatal injury through incorrect handling.
Only qualified electricians must operate or work on the electrical installation. The
plant must be isolated from mains power and secured against restarting during this
work. Observe all information about machine parts that remain live when the plant
is switched off at the main switch.
WARNING
Risk of injury through sudden plant startup!
When re-establishing the energy supply after an interruption, the plant can unexpect-
edly restart. This can cause severe injuries.
During maintenance work, switch off the plant and secure it against restarting (main
switches and shut-off valves). Observe the safety instructions in the plant documen-
tation. The plat operating personnel must receive regular training in operation and
handling of the plant and its components.
WARNING
Heavy weight of the module!
Improper handling can cause physical injuries of the worker!
For handling the module use suitable transport and lifting equipment!
WARNING
Pressurized material!
Technical defects or incorrect handling can cause pressurized material to escape.
Splashing or spraying material can cause severe eye injuries!
Carry out regular visual inspections of the material supply lines. Relieve the working
pressure before starting work. Wear your personal protective clothing.
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
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Central lubrication unit
General information Page 11 of 50
WARNING
Contact with solvents, adhesives and sealants!
Contact with eyes or skin causes injury.
Place the relevant safety data sheets in a clearly visible place on the plant and in-
structor the personnel. All work on the material supply lines and adjacent components
must be carried out only by trained, briefed specialists and with sufficient ventilation.
Within the area of the plant, eating, drinking, smoking, snuffing tobacco etc. is pro-
hibited. Dispose of spilt or escaped material immediately and according to regula-
tions. The specified protective clothing must be worn when working on the material
supply lines and adjacent components.
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
General information Page 12 of 50
1.8 Safety Measures
When working within the machine, the following protective equipment must be provide:
Always wear protective clothing and safety shoes according to accident
prevention and industrial safety regulations.
If necessary, use protective gloves or disposable gloves when working
on the material and hydraulic system.
When working on the material, compressed air and hydraulic system al-
so wear protective goggles.
When working within the machine wearing a head protection (protection
against bumping) is required.
NOTE
Check your protective clothing before each use!
1.9 Position numbers
The position numbers are specified in this document as follows: (Position number). These relate
to the technical drawings, which are indicated in the corresponding section.
The position number in the headings is indicated by (item XX).
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
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Central lubrication unit
Tools and accessories Page 13 of 50
2 Tools and accessories
The following tools and accessories are required for installation, uninstallation, maintenance
and repair of the assembly:
► Set of Allen keys
► Set of open-end spanners
► Oil filter spanner 93-45
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
Removing Page 14 of 50
3 Removing
3.1 Notes
► All work described here may only be carried out on a pressure- and voltage-free system.
The system must be protected against restarting.
► All work described here may only be carried out at a standstill.
The system must be secured against restarting.
► The safety and accident prevention regulations given in these documentations must also
be observed.
► Assembly work must be carried out by the manufacturer, by specially briefed personnel or
by trained personnel.
NOTE
If you have any questions, contact our customer service.
ABB Automation GmbH
Grüner Weg 6 | 61169 Friedberg | Germany
Tel.: [phone]
E-mail:
For further information, see our website
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
Removing Page 15 of 50
3.2 Removing of the container
•Release the clamp fasteners (51) on either side of the container.
Figure 1: Releasing the clamp fasteners
Item number Designation
(51) Clamp fastener
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Date: 2021-01-13
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Central lubrication unit
Removing Page 16 of 50
•Remove the square container (22) with the Mesamoll to be replaced.
Figure 2: Removing the container
Item number Designation
(22) Square container
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Date: 2021-01-13
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Central lubrication unit
Removing Page 17 of 50
•Remove the plate (4) from the container and hang the plate on the provided support
plate (2).
Figure 3: Taking off the lid
Item number Designation
(4) Plate
(2) Plate
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Date: 2021-01-13
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Central lubrication unit
Removing Page 18 of 50
•Unscrew the filling strainer (1) from the lid.
•Clean or replace the filling strainer.
Figure 4: Removing the filling strainer
Item number Designation
(1) Filling strainer
(5) Lid
DANGER
Danger through electric current!
Risk of serious or fatal injury through incorrect handling.
Only qualified electricians must operate or work on the electrical installation. The
plant must be isolated from mains power and secured against restarting during this
work. Observe all information about machine parts that remain live when the plant
is switched off at the main switch.
© 2021 ABB Automation GmbH | en

Date: 2021-01-13
Version: 1.2
Overhaul instructions
Central lubrication unit
Removing Page 19 of 50
3.3 Removing the filling strainer
•Unscrew the two thumb screws (40).
Figure 5: Removing thumb screws
Item number Designation
(40) Thumb screw
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Date: 2021-01-13
Version: 1.2
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Central lubrication unit
Removing Page 20 of 50
•Take the filling strainer complete with its lid (5) out of the plate.
Figure 6: Taking out the filter unit
Item number Designation
(5) Lid
© 2021 ABB Automation GmbH | en