GUDEL 404DLS User manual

404 DLS
OPERATING MANUAL
Automatic lubrication system
FlexxPump 404DLS
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG AUTOMATIC LUBRICATION SYSTEM FLEXXPUMP 404DLS99079191943154059_V10.0_EN-US
B1X.xxxxxxxxx-xxxx
09xxxxx
2019

© GÜDEL
Translation of the original instructions
This manual contains standard illustrations that may deviate from the original.
In the case of special models, options, or technical changes, the scope of deliv-
ery may differ from the descriptions here. Reprinting the instructions, in whole
or in part, requires our permission. Subject to change due to technical im-
provements.
99079191943154059_v10.0_EN-US

Revision history
Version Date Description
10.0 10/28/2019 New:
• Declaration of conformity for TriboServ
ÜChapter,2133
Entire manual updated.
9.0 02/27/2019 Updated:
• Type plate and location of type plate
Ü226
• Maintenance tasks Ü271
• Interim times for PIN4 output signal
Ü247 Ü249 Ü251 Ü253
• Recommended solution for software
programming Ü244
• Recommissioning Ü297
New:
• Overview of other applicable documen-
tation ÜChapter1.1,212
• Reference to lubrication requirements
ÜChapter5.4,243
• Reference to software modules
ÜChapter5.4,243
8.0 07/27/2018 Updated:
• Lubrication recommendation Ü255
• Checking the lubrication system
Ü259
• Checking the automatic lubrication sys-
tem Ü279
• Replacing the cartridge Ü272
• Maintenance table
New:
• Replacing the FlexxPump
ÜChapter7.3.4,280
Revision history
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
99079191943154059_v10.0_EN-US
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Version Date Description
7.0 06/01/2018 Valid as of FlexxPump serial number
1601929
Updated:
• Actuate ÜChapter5.4,243
• Lubrication recommendation Ü255
New:
• Splitter Ü229
ÜChapter4.2.3.1,233
6.0 04/12/2018 Updated:
• Lubrication check Ü259
5.0 12/12/2017 Updated:
• Lubrication check Ü259
4.0 08/08/2017 Added:
• Lubrication check Ü259
3.0 02/27/2017 Corrected:
• Standards and guidelines of the Declara-
tion of conformityDeclaration of con-
formity, declaration of incorporation
2.0 11/29/2016 Updated:
• New signatures on Declaration of con-
formityDeclaration of conformity, decla-
ration of incorporation
• Entire manual updated
1.0 07/29/2016 Basic version
Table-1 Revision history
Revision history
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
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Table of contents
1 General 11
1.1 Further applicable documentation................ .................12
1.2 Purpose of the document..................... ......................13
1.3 Explanation of symbols/abbreviations.............................. 14
2 Safety 15
2.1 General ...............................................................15
2.1.1 Product safety .........................................................15
2.1.2 Personnel qualifications..................................................16
2.1.2.1 Operating companies....................................................17
2.1.2.2 Transport specialists....................................................17
2.1.2.3 Fitters ................................ .................................17
2.1.2.4 Commissioning technicians ...................... .......................18
2.1.2.5 Operators .............................. ...............................18
2.1.2.6 Manufacturer's technicians.............................................. 18
2.1.2.7 Maintenance technicians.................................................19
2.1.2.8 Service technicians .......................... ...........................19
2.1.2.9 Disposal specialists.......................... ...........................19
2.1.3 Disregarding safety regulations.......................................... 20
2.1.4 Installation instructions..................................................20
2.2 Hazard symbols in the manual .....................................21
2.2.1 Hazard warnings .......................................................21
2.2.2 Explanation of warning symbol.......................................... 22
2.3 Fundamentals of safety..............................................22
2.3.1 Product-specific hazards.................................................22
2.3.2 Material safety data sheets (MSDS)...................................... 23
Table of contents
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3 Product description 25
3.1 Use ................................. ..................................25
3.1.1 Intended use............................. ..............................25
3.1.2 Non-intended use.......................................................25
3.2 Product designation........................ .........................26
3.2.1 Type plate .............................. ...............................26
3.2.2 Position of the type plate................................................27
3.3 Technical data........................... ............................27
3.3.1 FlexxPump..............................................................28
3.3.1.1 Dimensions and connections 404DLS................. ..................28
3.3.1.2 Temperature ranges.................................................... 29
3.3.1.3 IP protection class ..................................................... 29
3.3.1.4 Operating pressure......................................................29
3.3.2 Splitter .................................................................29
3.3.2.1 Temperature ranges.................................................... 29
3.3.2.2 Accuracy of the lubricant distribution................. ..................29
3.3.2.3 Minimum lubrication quantity..................... ......................30
3.3.2.4 Maximum pressure.......................... ...........................30
3.3.3 Lubricant amount .......................................................30
3.3.4 Shelf life of Güdel H1 lubricant.......................................... 30
4 Design, function 31
4.1 Design................................................................ 31
4.1.1 Detailed design of FlexxPump 404DLS ...................................32
4.2 Function .............................................................33
4.2.1 Functional description...................................................33
4.2.2 FlexxPump..............................................................33
4.2.2.1 404DLS................................................................ 33
4.2.3 Splitter .................................................................33
4.2.3.1 Function............................... ................................33
Table of contents
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5 Commissioning 35
5.1 Introduction .........................................................35
5.1.1 Safety.................................................................. 35
5.1.2 Personnel qualifications..................................................35
5.2 Transport ............................................................ 35
5.3 Installing .............................................................36
5.3.1 Prerequisites............................................................36
5.3.2 Installing the FlexxPump.................................................37
5.3.3 Connect hydraulics......................................................38
5.3.3.1 404DLS 3-fold ......................................................... 38
5.3.3.2 404DLS 6-fold ......................................................... 39
5.3.3.3 404DLS 10-fold .........................................................40
5.3.4 Connecting electrical equipment.........................................41
5.3.4.1 Connecting the 404DLS.................................................42
5.4 Actuate ...............................................................43
5.4.1 Suggested solution: Programming software...............................44
5.4.2 Connecting FlexxPump to power supply .................................45
5.4.3 Lubrication .............................................................47
5.4.4 Filling hydraulic lines / venting the FlexxPump............................ 49
5.4.5 Error message: Empty...................................................51
5.4.6 Error message: General..................................................53
5.4.7 Lubrication recommendation ..................... ......................55
5.4.7.1 General information.................................................... 55
5.4.7.2 Basics.................................................................. 56
5.4.7.3 Minimum lubrication quantity..................... ......................56
5.4.7.4 Calculation formulas.................................................... 57
5.5 Initial commissioning................................................ 58
5.5.1 Checking the lubrication system .........................................59
Table of contents
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6 Operation 64
6.1 General ...............................................................64
6.2 Personnel ............................................................ 64
6.3 Safety .................................................................65
7 Maintenance 67
7.1 Introduction .........................................................67
7.1.1 Safety.................................................................. 67
7.1.2 Personnel qualifications..................................................67
7.2 Consumables and auxiliary agents..................................68
7.2.1 Cleaning agents .........................................................68
7.2.1.1 Table of cleaning agents .................................................68
7.2.2 Lubricants ............................................................. 68
7.2.2.1 Lubrication .............................................................69
Automatic lubrication system........................................ 69
7.2.2.2 Lubricant table............................ .............................70
7.3 Maintenance tasks......................... ..........................71
7.3.1 Replacing the cartridge........................ .........................72
7.3.2 Checking the lubrication system .........................................75
7.3.3 Checking automatic lubrication system.................................. 79
7.3.4 Replacing the FlexxPump....................... ........................80
7.3.4.1 Disassembling the FlexxPump............................................80
7.3.4.2 Installing the FlexxPump.................................................81
7.3.4.3 Connect hydraulics......................................................82
404DLS 3-fold ...................................................... 82
404DLS 6-fold ...................................................... 83
404DLS 10-fold ..................................................... 84
7.3.4.4 Connecting electrical equipment.........................................85
7.3.4.5 Checking the lubrication system .........................................87
7.4 Maintenance table......................... ..........................91
Table of contents
OPERATING MANUAL Automatic lubrication system
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8 Repairs 93
8.1 Introduction .........................................................93
8.1.1 Safety.................................................................. 93
8.1.2 Personnel qualifications..................................................93
8.2 Repairs ............................... ................................93
8.3 Malfunctions / Troubleshooting.................. ...................94
8.4 Service departments................................................ 94
9 Decommissioning, storage 95
9.1 Introduction .........................................................95
9.1.1 Personnel qualifications..................................................95
9.2 Storage conditions ...................................................95
9.3 Decommissioning....................................................96
9.3.1 Shutdown.............................................................. 96
9.3.2 Cleaning, rust-proofing........................ .........................96
9.3.3 Identification............................................................96
9.4 Recommissioning.................................................... 97
10 Disposal 99
10.1 Introduction .........................................................99
10.1.1 Safety.................................................................. 99
10.1.2 Personnel qualifications..................................................99
10.2 Disposal .............................................................100
10.3 Waste management compliant assemblies........... ............100
10.3.1 Disassembly ...........................................................100
10.3.2 Material groups .......................................................101
10.4 Disposal facilities, authorities......................................101
Table of contents
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11 Accessories 103
11.1 PLC connecting cable .............................................. 103
12 Spare parts supply 105
12.1 Service departments....................... ........................107
12.2 Explanations regarding the spare parts list.......................113
12.2.1 Parts list...............................................................113
12.2.2 Position drawings .....................................................113
13 Torque tables 114
13.1 Tightening torques for screws................... ................... 114
13.1.1 Zinc plated screws ......................................................115
13.1.2 Black screws ............................................................116
13.1.3 Stainless steel screws ...................................................117
Illustrations 119
List of tables 121
Index 123
Appendix
Layout
Spare parts lists
Declaration of conformity for TriboServ
Table of contents
OPERATING MANUAL Automatic lubrication system
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1 General
Read the entire manual before working with the product. The manual con-
tains important information for your personal safety. The manual must be
read and understood by all persons who work on the product in any of the
product life phases.
General
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1.1 Further applicable documentation
All documents delivered with this manual are further applicable documenta-
tion. They must be observed in addition to this operating manual for the safe
handling of the product.
Document Explanation Target readership
FAQ: FlexxPump • Sales / project man-
agement
• Software engineer
• Maintenance techni-
cian
• Service technician
• Fitter
• Operating company
• Electrical engineer
Module Catalog only available in Ger-
man, French and Eng-
lish
Sales / project manage-
ment
Racks / Pinions Catalog Only available in Eng-
lish and Russian
Sales / project manage-
ment
Quick guide to check-
ing lubrication system
• Maintenance techni-
cian
• Service technician
• Fitters
Lubrication Control
Requirements
Only available in Eng-
lish
Software engineer
Lubrication quantity
calculator
• Only available in
English
• Only available as Mi-
crosoft Excel
• Sales / project man-
agement
• Software engineer
Software modules for
standard control sys-
tems
Only available as ZIP
file
Software engineer
Table1-1 Other applicable documentation
General
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1.2 Purpose of the document
This manual describes all the product life phases of the product:
• Transport
• Commissioning
• Operation
• Maintenance
• Repairs
• Disposal
The manual contains the information required for using the product as in-
tended. It is an essential component of the product.
The manual must be available at the product site throughout the entire ser-
vice life of the product. If the product is sold, the manual must be transferred
to the new owner.
General
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1.3 Explanation of symbols/abbreviations
The following symbols and abbreviations are used in this manual:
Symbol/Abbrevia-
tion
Use Explanation
Ü
For cross-reference See
2
Possibly for cross-ref-
erence
Page
Fig. Designation of graphics Figure
Table Designation of tables Table
In the tip Information or tip
Table1-2 Explanation of symbols/abbreviations
General
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2 Safety
2.1 General
Read the entire manual before working with the product. The manual con-
tains important information for your personal safety. The manual must be
read and understood by all persons who work on the product in any of the
product life phases.
2.1.1 Product safety
Residual danger The product is built using state-of-the-art technology. It was designed and
constructed in accordance with the accepted safety regulations. However,
some residual danger remains during its operation.
There is danger to the personal safety of the operator as well as for the prod-
uct and other property.
Operation When operating the product, always observe this manual and ensure that the
system is always in perfect working order.
Safety
OPERATING MANUAL Automatic lubrication system
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2.1.2 Personnel qualifications
WARNING
Lack of safety training
Incorrect behavior of untrained or insufficiently trained technicians can result
in severe or fatal injuries!
Before technicians work on safety-related aspects of the product:
• Ensure that the technicians are trained with regard to safety
• Train and instruct the technicians specifically for their area of responsibility
Only appropriately trained and authorized technicians are allowed to work on
the product.
Persons are authorized if:
• they are familiar with the relevant safety regulations for their area of re-
sponsibility
• they have read and understood this manual
• they meet the requirements for an area of responsibility
• they were assigned an area of responsibility by the operator
The technician is responsible to third parties in his area of responsibility.
During a training session or instruction, the technician may only work on the
product under the supervision of an experienced manufacturer's technician.
Safety
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2.1.2.1 Operating companies
The operating company is responsible for ensuring that:
• the product is used as intended
• the product is sufficiently lubricated at all times
• all safety aspects are complied with
• the product is put out of operation if the functioning of the safety equip-
ment is not fully guaranteed
• the technician working on the product is appropriately trained
• the technician is provided with personal protective equipment
• the operating manual is available to the technician at the operation site of
the product at all times
• the technicians are kept up-to-date regarding best practice
• the technicians are informed about technical progress, modifications, and
the like.
• the contracted cleaning staff only work under the supervision of a mainte-
nance technician
2.1.2.2 Transport specialists
The transport specialist:
• is able to transport loads safely
• is able to use slings safely and properly
• is able to secure the load properly
• has experience in transportation
2.1.2.3 Fitters
The fitter:
• has very good mechanical and/or electrical knowledge
• is flexible
• has assembly experience
Safety
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2.1.2.4 Commissioning technicians
The commissioning technician:
• has good programming knowledge
• has mechanical and/or electrical knowledge
• is flexible
The commissioning technician is responsible for the following tasks:
• commissioning the product
• testing the functions of the product
2.1.2.5 Operators
The operator:
• was trained and instructed by the operating company or the manufacturer
• has very good knowledge of the user interface and the operating elements
• has process knowledge which is specifically geared to the product
The operator is responsible for the following tasks:
• switching the control system of the product on and off
• creating production readiness
• monitoring the production process
• localizing minor malfunctions
2.1.2.6 Manufacturer's technicians
The manufacturer's technician:
• is employed on site at the premises of the manufacturer or representative
• has very good mechanical and/or electrical knowledge
• has good software knowledge
• has maintenance, service and repair experience
• has experience with Güdel products
The manufacturer's technician is responsible for the following tasks:
• performing mechanical and electrical maintenance work in accordance with
the manual
• performing mechanical and electrical service work in accordance with the
manual
• cleaning the product
• replacing spare parts
• localizing and fixing malfunctions
Safety
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2.1.2.7 Maintenance technicians
The maintenance technician:
• was trained by the operating company or the manufacturer
• has very good mechanical and/or electrical knowledge
• has software knowledge
• has maintenance experience
• bears responsibility for the safety of the cleaning staff
The maintenance technician is responsible for the following tasks:
• performing mechanical and electrical maintenance work in accordance with
the manual
• cleaning the product
• replacing spare parts
• monitoring and instructing the cleaning staff in the safety zone during the
cleaning process
2.1.2.8 Service technicians
The service technician:
• was trained by the operating company or the manufacturer
• has very good mechanical and/or electrical knowledge
• has software knowledge
• has service and repair experience
• is flexible
The service technician is responsible for the following tasks:
• performing mechanical and electrical service work in accordance with the
manual
• replacing spare parts
2.1.2.9 Disposal specialists
The disposal specialist:
• is able to separate waste
• is familiar with the country-specific disposal regulations
• has experience in environmentally-friendly disposal
• works carefully and safely
Safety
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2.1.3 Disregarding safety regulations
DANGER
Disregarding safety regulations
Disregarding safety regulations can result in damage to property, severe or
fatal injuries.
• Always comply with the safety regulations
Liability Güdel shall not be held liable under any of the following circumstances:
• The installation regulations were disregarded
• Included protective equipment was not installed
• Included protective equipment was modified
• Included monitoring equipment was not installed
• Included monitoring equipment was modified
• The product was not used as intended
• The maintenance work was not performed in the specified intervals, or
was carried out incorrectly.
2.1.4 Installation instructions
Protective mea-
sures
The operating company is responsible for ensuring safe conditions in the vicin-
ity of the product. In particular, he must ensure compliance with the general
safety regulations, guidelines and standards. Before commissioning the system
the operating company must check whether all the protective measures have
been implemented. These must cover all hazards. This is the only way to en-
sure that application of the product conforms to CE regulations.
As stipulated by the Machinery Directive, the protective measures must:
• Correspond to best practices
• Comply with the required safety category
Modifications The product must never be modified or used in a manner contrary to its in-
tended use. Ü225
General rules for
occupational
safety
The generally accepted occupational safety rules must be observed and imple-
mented.
Safety
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